Bomag BW177D 50 OperatorsManual

Printed in U.S.A.
BOMAG Americas, Inc.

2000 Kentville Rd.
Kewanee, IL 61443
Catalog Number
0852820 4/12
Operating Instructions
Maintenance Instructions
BW177D-50 / BW177DH-50 / BW177PDH-50
SN: 901582301001 > SN: 901582311001 >
SN: 901582321001 >
Single Drum Vibratory Roller
SYMBOLS USED IN THIS MANUAL
The following symbols have been used in THIS Manual to help communicate the intent of instructions.
When one of the symbols appears, it conveys the meaning defned below:
Serious personal injury, death, and/or
extensive property damage can result
if the DANGER instructions are not
followed.
Minor personal injury can result or a
part, an assembly, or the engine can be
damaged if the CAUTION instructions
are not followed.
Serious personal injury and/or extensive
property damage can result if the
WARNING instructions are not followed.
NOTE: Gives additional, and/or clarifcation
details, which are to be used in
conjunction with previously presented
information.
CALIFORNIA
Proposition 65 Warning
WARNING: Diesel engine exhaust and
some of its constituents are known to the
state of California to cause cancer, birth
defects, and other reproductive harm.
CALIFORNIA
Proposition 65 Warning
WARNING: Battery posts, terminals and
related accessories contain lead and lead
compounds, chemicals known to the state
of California to cause cancer, birth defects,
and other reproductive harm.
Wash hands after handling.
BOMAG machines are products from the wide range
of BOMAG compaction equipment.
BOMAGs vast experience in connection with state-
of-the-art production and testing methods, such
as lifetime tests of all important components and
highest quality demands guarantee maximum
reliability of your machine.
This manual comprises:
Safety regulations
Operating instructions
Maintenance instructions
Trouble shooting
Using these instructions will
help you to become familiar with the machine.
avoid malfunctions caused by unprofessional
operation.
Compliance with the maintenance instructions will
enhance the reliability of the machine on con-
struction sites,
prolong the lifetime of the machine,
reduce repair costs and downtimes.
BOMAG will not assume liability for the function of the
machine
if it is handled in a way not complying with the
usual modes of use,
if it is used for purposes other than those men-
tioned in these instructions.
No warranty claims can be lodged in case of damage
resulting from
operating errors,
insufficient maintenance and
wrong fuels and lubricants.
Please note!
This manual was written for operators and maintenance
personnel on construction sites.
Always keep this manual close at hand, e.g. in the
tool compartment of the machine or in a specially
provided container. These operating and maintenance
instructions are part of the machine.
You should only operate the machine after you have been
instructed and in compliance with these instructions.
Strictly observe the safety regulations.
Please observe also the guidelines of the Civil
Engineering Liability Association Safety Rules for the
Operation of Road Rollers and Soil Compactors and all
relevant accident prevention regulations.
For your own personal safety you should only use
original spare parts from BOMAG.
In the course of technical development we reserve
the right for technical modifcations without prior
notifcation.
These operating and maintenance instructions are also
available in other languages.
Apart from that, the spare parts catalogue is avail-able
from your BOMAG dealer against the serial number of
your machine.
Your BOMAG dealer will also supply you with information
about the correct use of our machines in soil and asphalt
construction.
The above notes do not constitute an extension of the
warranty and liability conditions specifed in the general
terms of business of BOMAG. We wish you successful
work with your BOMAG machine.
Copyright by BOMAG
Fig. 1
Fig. 2
Fig. 3
Please fll in
...........................................................................................................
Machinetype(Fig. 1)
...........................................................................................................
Serial No. (Fig. 1 and 2)
...........................................................................................................
Engine type (Fig. 3)
...........................................................................................................
Engine No. (Fig. 3)
Note: Fill in the above listed data when receiving
the machine.
Upon receipt of the machine our
organization will instruct you about
correct operation and maintenance.
Please observe strictly all safety
regulations and notes on potential
dangers!
Table of Contents
Technical Data Section 1
Safety Regulations Section 2
Indicators and Controls Section 3
Operation Section 4
Maintenance Section 5
Trouble Shooting Section 6
1-1
Section 1
TECHNICAL DATA
4-2012
TABLE OF CONTENTS
PAGE
TECHNICAL DATA .......................................................................................................................... 2
H2
H
D
K
A
L
O1 W
B
O2
S
Section 1
TECHNICAL DATA
1-2 4-2012
Dimensions
in mm (in)
A B D H H2 K L O1 O2 S W
BW 177D-50 2500
(98.4)
1816
(71.5)
1228
(48.3)
2225
(87.6)
2860
(112.6)
375
(14.7)
4913
(193.4)
65
(2.6)
65
(2.6)
25
(1.0)
1686
(66.4)
Fig. 4
* BW 177 D-50
Weights
Operating weight (CECE) with
ROPS
kg(lbs) 6965 (15,355)
with Cabin kg(lbs) 7205 (15,880)
Axle load, drum (CECE) with ROPS kg(lbs) 4100 (9,040)
Rear axle load (CECE) with ROPS kg(lbs) 2865 (6,315)
Static linear load with ROPS kg/cm (lbs/in) 24.3 (136.1)
Travel characteristics
Travel speed (1) km/h(mph) 0 ... 7 (0-4.3)
Travel speed (2) km/h(mph) 0 ... 11 (0-6.8)
Max. gradability
(depending on soil)
% 45
Engine
Engine manufacturer Cummins
Type B3.3T
Cooling Water
Number of cylinders 4
Rated power DIN ISO 14396 kW (hp) 55 (74)
Rated speed 1 rpm 2600
Fuel Diesel
1-3
Section 1
TECHNICAL DATA
4-2012
* The right for technical modifcations remains reserved
** With flter
* BW 177 D-50
Electrical equipment V 12
Drive system hydrostatic
Driven axles 2
Brakes
Service brake hydrostatic
Parking brake hydr.-mech.
Steering
Type of steering articulated
Steering operation hydrostatic
Vibration
Vibrating drum 1
Drive system hydrostatic
Frequency Hz (VPM) 30/40 (1,800/2,400)
Amplitude mm (in) 1,8/0,9 (.071/.035)
Tires
Tire size 14.9-24/6PR
Tire tread Diamond (R3)
Air pressure bar (psi) 1,9 (27.6)
Filling capacities
Engine Oil** Litres (gal) 8.5 (2.24)
Fuel Litres (gal) 150 (40)
Hydraulic oil Litres (gal) 60 (16)
Coolant W/O Heating Litres (gal) 23.5 (6.2)
Coolant W/ Heating Litres (gal) 25.5 (6.73)
H2
H
D
K
A
L
O1 W
B
O2
S
Section 1
TECHNICAL DATA
1-4 4-2012
Dimensions in
mm (in)
A B D H H2 K L O1 O2 S W
BW 177DH-50 2500
(98.4)
1816
(71.5)
1228
(48.3)
2225
(87.6)
2860
(112.6)
375
(14.7)
4913
(193.4)
65
(2.6)
65
(2.6)
25
(1.0)
1686
(66.4)
BW 211PDH-50 2500
(98.4)
1816
(71.5)
1228
(48.3)
2225
(87.6)
2860
(112.6)
375
(14.7)
4913
(193.4)
65
(2.6)
65
(2.6)
25
(1.0)
1686
(66.4)
Fig. 4
* BW 177DH-50 BW 211 PDH-50
Weights
Operating weight (CECE) with
ROPS
kg(lbs) 7095 (15,640) 7310 (16,115)
with Leveling Blade kg(lbs) N/A 7910 (17,440)
with Cabin kg(lbs) 7340 (16,160) 7550 (16,640)
Axle load, drum (CECE) with ROPS kg(lbs) 4115 (9,070) 4330 (9,545)
with Leveling Blade kg(lbs) N/A 4835 (10,660)
Rear axle load (CECE) with ROPS kg(lbs) 2980 (6,570) 2980 (6,570)
Static linear load with ROPS kg/cm (lbs/in) 24.4 (136.6)
Travel characteristics
Travel speed (1) km/h(mph) 0 ... 4.0 (2.5) 0 ... 4.0 (2.5)
Max. gradability
(depending on soil)
% 55 55
Engine
Engine manufacturer Cummins Cummins
Type B3.3T B3.3T
Cooling Water Water
Number of cylinders 4 4
Rated power DIN ISO 14396 kW (hp) 55 (74) 55 (74)
Rated speed 1 rpm 2600 2600
Fuel Diesel Diesel
1-5
Section 1
TECHNICAL DATA
4-2012
* The right for technical modifcations remains reserved
** With flter
* BW 177 DH-50 BW 177 PDH-50
Electrical equipment V 12 12)
Drive system hydrostatic hydrostatic
Driven axles 2 2
Brakes
Service brake hydrostatic hydrostatic
Parking brake hydr.-mech. hydr.-mech.
Steering
Type of steering articulated articulated
Steering operation hydrostatic hydrostatic
Vibration
Vibrating drum 1 1
Drive system hydrostatic hydrostatic
Frequency Hz (VPM) 30/40 (1,800/2,400) 30/40 (1,800/2,400)
Amplitude mm (in) 1,8/0,9 (.071/.035) 1,70/0,9 (.064/.035)
Tires
Tire size 14.9-24/6PR 14.9-24/6PR
Diamond (R3) Tractor (R1)
Air pressure bar (psi) 1,9 (27.6) 1,6 (23.2)
Filling capacities
Engine Oil ** Litres (gal) 8.5 (2.24) 8.5 (2.24)
Fuel Litres (gal) 150 (40) 150 (40)
Hydraulic oil Litres (gal) 60 (16) 60 (16)
Coolant W/O Heating Litres (gal) 23.5 (6.2) 23.5 (6.2)
Coolant W/ Heating Litres (gal) 25.5 (6.73) 25.5 (6.73)
Section 1
TECHNICAL DATA
1-6 4-2012
NOTES
2-1
Section 2
SAFTEY REGULATIONS
4-2012
PAGE
GENERAL ....................................................................................................................................... 3
LOADING THE MACHINE .............................................................................................................. 4
TOWING THE MACHINE ............................................................................................................... 4
STARTING THE MACHINE ............................................................................................................. 4
BEFORE STARTING .................................................................................................................... 4
STARTING ................................................................................................................................ 5
STARTING WITH JUMP LEADS ............................................................................................... 5
STARTING IN CLOSED ROOMS .............................................................................................. 5
DRIVING THE MACHINE ............................................................................................................... 5
DRIVING ON SLOPES AND GRADIENTS .................................................................................. 6
CHECK THE EFFECT OF VIBRATION ............................................................................................ 6
PARKING THE MACHINE .............................................................................................................. 6
PARKING ON SLOPES AND GRADIENTS .................................................................................. 6
FILLING THE FUEL TANK .............................................................................................................. 6
FIRE PROTECTION MEASURES .................................................................................................... 6
MAINTENANCE WORK ................................................................................................................. 6
WORKING ON HYDRAULIC LINES ............................................................................................... 7
CHANGING HYDRAULIC HOSES ............................................................................................... 7
WORKING ON THE ENGINE .......................................................................................................... 7
WORKING ON ELECTRICAL EQUIPMENT ................................................................................... 7
WORKING ON THE BATTERY .................................................................................................... 7
WORKING ON THE FUEL SYSTEM ............................................................................................... 8
TABLE OF CONTENTS
Section 2
SAFTEY REGULATIONS
2-2 4-2012
WORKING ON WHEELS AND TIRES ............................................................................................. 8
CLEANING ..................................................................................................................................... 8
AFTER MAINTENANCE WORK ..................................................................................................... 8
REPAIR ........................................................................................................................................... 8
TEST ............................................................................................................................................... 8
2-3
Section 2
SAFTEY REGULATIONS
4-2012
General
This BOMAG machine is built in accordance with
the latest technical standard and the valid technical
rules and regulations. There is, however, a risk of
danger for persons and property if:
the machine is used for purposes other than
those it is intended for
the machine is operated by untrained personnel
the machine is modified or converted in an
unprofessional way
the applicable safety regulations are not
observed.
Each person involved in operation, maintenance and
repair of the machine must therefore read and apply
these safety regulations. This should be confrmed
by obtaining the signatures of the customer, if
necessary.
Furthermore the following regulations and instructions
are obviously also valid:
applicable accident prevention instructions
generally acknowledged safety and road traffic
regulations
country specific safety regulations. It is the duty
of the operator to know and observe these
regulations. This applies also for local regulations
and the regulations for various types of manual
work. If the recommendations in this manual
differ from the regulations valid in your country,
you must strictly observe the regulations in your
country.
Intended use
This machine must only be used for:
compaction of bituminous materials, e.g. road
surface layers. (AC and AD machines only)
medium and heavy compaction tasks in earth
work (road sub-bases)
This machine must only be operated with fully
functional safety equipment.
The machine should be checked by an expert
once every year.
Unintended use
Dangers may, however, arise from the machine if it is
used by untrained personnel in an unprofessional way
or if it is used for purposes other than those mentioned
in these instructions.
Do not work with vibration on hard concrete, on a cured
concrete layer or heavily frozen ground.
Starting and operation of the machine in an explosive
environment is prohibited.
Who is allowed to work with the machine?
The machine must only be operated by trained and
authorized persons which are at least 18 years of age.
The responsibilities for the operation of the machine
must be clearly specifed and complied with.
Persons under the infuence of alcohol, medication or
drugs must not operate, service or repair the machine.
Maintenance and repair tasks require specifc knowledge
and must therefore only be carried out by trained and
qualifed personnel.
Conversions and alterations to the machine
Unauthorized conversions to the machine are prohibited
for safety reasons.
Original parts and accessories have been specially
designed for this machine. We wish to make expressly
clear that we have not tested or authorized any original
parts or special equipment not supplied by us. The
installation and/or use of such products can impair the
active and/or passive driving safety. The manufacturer
expressly excludes any liability for damage resulting
from the use of non-original parts or accessories.
Safety notes in the operating and maintenance
instructions:
Sections marked like this point out
possible dangers for persons.
Section 2
SAFTEY REGULATIONS
2-4 4-2012
Sections marked like this point out
possible dangers for the machine or for
parts of the machine.
Note: Sections marked like this provide
technical information concerning the
optimal economical use of the machine.
Sections marked like this
highlight activities for the safe
and environmental disposal of
fuels and lubricants as well as
replaced parts.
Observe al l envi ronment
protection regulations.
Information and safety stickers/decals on the
machine
Keep stickers/decals complete (see spare parts
catalogue) and fully legible and observe their meaning.
Replace damaged or illegible stickers/decals
immediately.
Loading the machine
Use only strong and stable loading ramps. The ramp
inclination must be lower than the gradability of the
machine.
Secure the machine against turning over or slipping of.
Secure the machine on the transport vehicle against
rolling of, slipping and turning over.
Persons are highly endangered if:
they step or stand under loads being lifted
they remain in the drive range of the machine
during a demonstration or during loading.
The machine must not swing about when lifted of the
ground.
Use only safe lifting gear of sufcient load bearing
capacity.
Attach the lifting gear only to the specifed lifting points.
Towing the machine
Since the machine is notftted with a towing hitch, the
machine cannot be towed with a tow bar.
If the machine has to be towed urgently out of the danger
zone because of other risks, this must only be done on
level ground or uphill using chains and ropes. For this
purpose towing ropes of sufcient tensile strength must
be fastened on the lifting eyes.
After releasing the brake the machine can only be braked
by the towing vehicle.
Before releasing the brake block the machine with
chocks to prevent unintended rolling.
Checking the Roll Over Protection Structure (ROPS)
The machine frame must not be distorted, bent or
cracked in the area of the ROPS structure.
The ROPS structure must not show any rust, damage,
hairline cracks or open fractures.
The ROPS must not rattle about when driving the
machine. This would mean that the fastening screws
are insufciently fastened. All screwed connections
must be tight and in accordance with the specifcations
(observe the tightening torques). Screws and nuts must
not be damaged, distorted or deformed.
No additional parts must be welded or bolted on and
no holes must be drilled without the permission of the
dealer, since this may impair the strength of the structure.
Starting the machine
Before starting
Operation of the machine is only permitted when sitting
in the operators seat.
Use only machines which have been properly serviced
at regular intervals.
Become acquainted with the equipment, the control
elements, the working mode of the machine and the
area you will be working in.
Use your personal protective outft (hard hat, safety
boots etc.).
Check before mounting the machine if:
there are persons or obstructions beside or under
the machine
Environment
2-5
Section 2
SAFTEY REGULATIONS
4-2012
the machine is free of any oily and combustible
material
all handrails, steps and platforms are free of
grease, oils, fuels, dirt, snow and ice
the engine compartment hood is closed and
locked
To climb onto the machine use steps and handrails.
Check before starting, whether:
the machine shows any obvious defects
all protective devices are properly secured in
their place
steering, brakes, control elements, lighting and
warning horn are in order
the seat is correctly adjusted
the mirrors (if available) are clean and correctly
adjusted.
Do not start the machine if any gauges, control lights
or controls are defective.
Do not take any loose objects with you or fasten them
to the machine.
On machines with ROPS you should always wear your
seat belt!
Starting
Start and operate the machine only from the operators
seat
For starting set all control levers to neutral position.
Do not use any starting aids such as Start Pilot or ether.
After starting check all gauges.
Starting with jump leads
Connect plus with plus and minus with minus (ground
cable) - always connect the ground cable last and
disconnect it frst! Wrong connections may cause
severe damage in the electric system.
Never start the engine by bridging the electrical
connections on the starter, because the machine would
probably start to move immediately.
Starting in closed rooms
Exhaust gases are toxic! Always ensure an adequate
supply of fresh air when starting in closed rooms!
Driving the machine
Persons in the endangered area
If the machine has turned over and the cabin door
is jammed, use the right hand cabin window as an
emergency exit.
Check if there are persons or obstacles in the danger
area before starting or resuming work, especially when
driving in reverse.
I f necessary give warning signals. Stop work
immediately if persons remain in the danger area
despite the warning.
Do not step or stand into the articulation area of the
machine while the engine is running. Danger of injury!
Driving
In events of emergency actuate the emergency stop
switch immediately. Do not use the emergency stop
push button as service brake.
Restart the machine only after the danger, that has
caused the actuation of the emergency stop, has been
eliminated.
If the machine has come in contact with high-voltage
power lines:
do not leave the operators stand
warn others from coming too close to the
machine or touching it
if possible drive the machine out of the danger
zone
have the power shut off.
Operate the machine only from the operators seat.
Keep the cabin doors closed.
Do not adjust the operators seat while driving.
Do not climb onto or of the machine while driving.
Change the travel direction only while the machine is
standing.
Do not use the machine to transport persons.
Stop the machine if you notice unusual noises or the
development of smoke. Investigate the cause and have
the fault corrected.
Always keep a safe distance to excavations and
embankments and avoid all activities which could impair
the stability of the machine.
Section 2
SAFTEY REGULATIONS
2-6 4-2012
Do not work with vibration on hard concrete, on a cured
concrete layer or heavily frozen ground.
When passing under fyovers, bridges, tunnels, electric
power lines etc. keep a sufcient distance.
Driving on slopes and gradients
Do not drive up and down gradients, which exceed the
maximum gradability of the machine.
Always drive extremely carefully on slopes and always
directly up or down the slope, never diagonally. Change
to the lower speed range before approaching the
inclination.
Wet and loose soils reduce the ground adhesion of
the machine and inclinations and slopes considerably.
Higher risk of accident!
Behaviour in trafc
Match the speed of the machine to the working
conditions.
Always allow loaded transport vehicles to pass.
Switch the lights on when the visibility is poor.
Keep clear of edges and embankments.
Check the efect of vibration
When compacting with vibration check the efect of the
vibration on nearby buildings and underground supply
lines (gas, water, sewage, electric power supply), stop
vibratory compaction if necessary.
Never use the vibration on hard (frozen, concrete)
ground. Risk of bearing damage!
Parking the machine
Park the machine on level and frm ground.
Before leaving the machine:
straighten the articulated joint to allow easy
access to and from the machine.
return the travel lever to neutral position
apply the parking brake
shut the engine down and pull the ignition key
out.
lock the cabin door
secure the machine against unauthorized use.
Do not jump of the machine, use access steps and
hand rails.
Always secure parked machines, which could be in the
way, with appropriate measures.
Parking on slopes and gradients
Secure the machine against rolling, place metal chocks
in front of and behind the drums.
Filling the fuel tank
Do not inhale fuel fumes.
Refuel only after shutting the engine and the auxiliary
heater down.
Do not refuel in closed rooms.
No open fre, do not smoke.
Do not spill any fuel. Catch running out fuel, do not let
it seep into the ground.
Wipe of spilled fuel. Keep fuel free of dirt and water.
Leaking fuel tanks can cause explosions. Ensure tight
ft of the fuel tank flling cover, replace it if necessary.
Fire protection measures
Make yourself acquainted with the location and the
operation of fre extinguishers. Observe fre warning
and fre fghting installations.
Maintenance work
Strictly apply the specifed maintenance tasks, including
the changing of parts.
For service and repair work in the engine compartment
support the engine compartment hood
Maintenance work must only be carried out by qualifed
and authorized personnel.
In case of maintenance and assembly work over-head
make sure to use the prescribed or other safe access
steps, ladders and gangways. Do not use parts of the
machine as access steps. Keep unauthorized persons
away from the machine.
Keep unauthorized persons away from the machine.
Do not perform maintenance work with the machine
driving or the engine running.
Park the machine on horizontal, level and stable ground.
Pull the key out of the ignition switch.
Lock the articulated joint with the articulation lock.
2-7
Section 2
SAFTEY REGULATIONS
4-2012
Working on hydraulic lines
Always relieve the pressure in the hydraulic circuit
before working on hydraulic lines. Hydraulic oil escaping
under pressure may penetrate through the skin and
cause severe injury. In case of being injured by hydraulic
oil you should immediately seek medical advice, as
otherwise this may lead to serious infections.
When adjusting the hydraulic system do not stand
behind or in front of the drum/wheels.
Do not change the setting of high pressure relief valves.
Drain hydraulic oil at operating temperature - danger
of scalding!
Catch running out hydraulic oil and dispose of
environmentally.
Always catch and dispose of biological hydraulic oils
separately.
Do not start the engine after draining of the hydraulic
oil.
Once all work is completed (with the system
depressurized!) check all connections and fttings for
tight and leak-free ft.
Changing hydraulic hoses
All hydraulic hoses must be inspected visually at regular
intervals.
Hydraulic hoses must be changed immediately if:
damage to the outer surface down to the lining
(e.g. chafings, cuts, cracks)
embrittlement of the outer layer (development
of cracks in the hose material)
deformation under pressurized and
depressurized condition, which are not in
accordance with the normal shape of the
hydraulic hose
deformation in bends, e.g, squeezes, kinks, layer
separation, formation of blisters
leakages.
non-observance of the installation requirements
separation of the hydraulic hose from the fitting
corrosion of the fitting, which impairs the
function and the strength.
Do not mix up hoses by mistake.
damage or deformation of the fitting, which
impairs the function and strength of the hose/
hose connection.
Only genuine BOMAG hydraulic hoses ensure that the
correct type of hose (pressure range) is used at the
right place.
Working on the engine
Shut the engine down before opening the engine
compartment hood.
Drain the engine oil at operating temperature - danger
of scalding!
Wipe of spilled oil, catch running out oil and dispose
of environmentally.
Store used filters and other oily materials in a
separate, specially marked container and dispose of
environmentally.
Do not leave any tools or other objects, which could
cause damage, in the engine compartment.
Idle speed and full load speed must not be changed,
since this would have a negative efect on the exhaust
gas values and cause damage to engine and drive.
Turbo chargers work with high speeds and high
temperatures. Keep hands, tools and materials away
from the intake and outlet openings of the turbo charger
and do not touch any hot surfaces. Check and replace
the coolant only when the engine is cold.
Catch runni ng out cool ant and di spose of
environmentally.
Working on electrical equipment
Before working on electrical equipment disconnect the
battery and cover it with insulating material.
Do not use any fuses with higher ampere ratings or
repair a fuse with a piece of wire. Fire hazard!
Always disconnect the battery before starting to weld
on the machine.
Working on the battery
When working on the battery do not smoke, do not
use open fre.
Section 2
SAFTEY REGULATIONS
2-8 4-2012
Do not let acid come in contact with skin and clothes.
If being injured by acid fush of with clear water and
seek for medical advice.
Metal objects (e.g. tools, rings, wrist watches) must
not contact the battery poles - danger of short circuit
and burns!
When recharging maintenance free batteries remove
the plugs to avoid the accumulation of explosive gases.
When using an external battery to start the machine
follow the respective instructions.
Dispose of old batteries environmentally.
Switch the charging current of before removing the
charge clamps.
Ensure good ventilation, especially when charging the
battery in a closed room.
Working on the fuel system
Do not inhale fuel fumes.
No open fre, do not smoke, do not spill any fuel.
Catch running out fuel, do not let it seep into the ground
and dispose of environmentally.
Working on wheels and tires
Explosion like bursting of tires and parts of rims and
tires can cause severe or even deadly injuries.
The assembly of tires must only be carried out
by experienced personnel and with the correct
equipment. If necessary have the tires assembled in
a qualifed workshop.
Ensure correct tire pressure and do not exceed the
highest specifed pressure.
Check wheels and tires every day for specifed pressure,
cuts, bulges, damaged wheel rims, missing wheel studs
and nuts. Do not drive with damaged tires or wheels.
Anti-stick emulsions for tires must only be mixed using
water and concentrated anti-stick agent according to
the specifcations of the manufacturer of the anti-stick
agent. Observe the regulations for the protection of
the environment.
Cleaning
Do not clean the machine while the engine is running.
Do not use gasoline or other combustible substances
for cleaning purposes.
When using steam cleaning equipment do not subject
electrical components and insulating materials to the
direct water jet, but cover them beforehand.
Do not guide the water jet into the exhaust or
into the air filter.
After maintenance work
Reinstall all protective devices after completing the
maintenance work.
Repair
Attach a warning tag to the steering wheel if the
machine is defective.
Repairs must only be performed by qualifed persons
who have been instructed for this purpose. Use our
repair instructions.
Exhaust gases are highly dangerous! Always ensure an
adequate supply of fresh air when starting in closed
rooms!
Test
Depending on the type of application and the operating
conditions vibratory equipment has to be examined
by a specialist whenever required, but at least once
every year.
3-1
Section 3
INDICATORS AND CONTROLS
4-2012
TABLE OF CONTENTS
PAGE
GENERAL NOTES ........................................................................................................................... 4
DESCRIPTION OF INDICATORS AND CONTROL ELEMENTS...................................................... 4
Section 3
3-2
4-2012
Fig. 6
3-3
Section 3
4-2012
1 Ignition switch
2 Instrument cluster
3 Vent for heating and ventilation, driver
3
4 Vent for heating and ventilation, footwell
3
5 Push button vibration
6 Travel lever
7 Rotary switch vibration, high/low frequency
8 Rotary switch for speed limitation control
9 Emergency stop push button
10 Push button for warning horn
11 Warring light ASC Anti-Spin-Control
1

12 Rotary switch for direction indicators left/right
3

13 Rotary switch for hazard light system
3

14 Rotary switch for lighting (StVZO)
3
15 Rotary switch for working lights
3
16 Steering wheel adjustment lever
3
17 Rotary momentary contact switch for engine
speed and engine diagnotics inc/dec.
1 BW177DH/PDH-50
2 Not Available
3 Optional Equipment
Section 3
3-4
4-2012
General notes Description of indicators and control
elements
Fig. 7
No. 1 = Ignition switch
Please read this section thoroughly before operating
this machine if you are not yet conversant with the
indicators and control elements. All functions are
described in detail hereunder.
Paragraph 4 Operation contains only concise
descriptions of the individual operating steps.
NOTE: The engine can only be started when the
travel lever is in braking position.
The ignition switch is provided with a lock
against repetitive starting. To repeat the
starting procedure you must frst turn the
ignition switch back to 0- position.
Position P = accessories on, ignition of, the
key can be pulled out, engine
not running.
Position 0 = ignition of, the key can
be pulled out, engine not
running.
Position I = ignition on, all control and
warning lights on the fault
monitoring board light up for
a moment. The lighting can be
switched on.
Position II = not used
Position III = turn further against spring
pressure, the engine starts.
Allow the ignition key to return
to the I position when the
engine starts.
Run the engine warm for a short while
before starting to work. Do not let the
engine run at idling speed for longer
than 10 minutes.
Do not shut the engine down all of
a sudden from full speed, but let
it idle for a while for temperature
equalization.
3-5
Section 3
4-2012
Fig. 8
No. 2 = Instrument cluster
NOTE: With the ignition switch in position I all
gauges and instruments are switched on
for 3 seconds.
a red = fashes when the engine
overheats, the warning buzzer
sounds, the engine is shut
down after 2 minutes. Switch
of vibration, run engine
with idle speed or shut down
engine if necessary, clean
engine oil cooler and radiator,
if necessary repair engine.
b red = fashes if engine oil pressure
too low, engine is shut down
after 10 seconds. Check engine
oil level, repair the engine if
necessary.
c yellow = N/A
d yellow = Charge control light, lights if
battery is not being charged.
Check V-belt, if necessary
repair the generator.
e yellow = lights if the hydraulic oil flter
is contaminated, the engine
is shut down after 2 minutes.
Check hydraulic system,
replace hydraulic oil flter.
f yellow = N/A
g red = Parking brake, with lever shifted
to parking brake position, with
drivers seat unoccupied.
h green = Direction indicator*, fashes
when the direction indicator
switch is actuated.
i yellow = Water separator in fuel pre-
cleaner. Lights when the water
proportion in the fuel flter
reaches the contacts.
j red = N/A
k yellow = Glow Plugs indicator lights
when temperature is low
(pre-heating for starting)
l red = Hazard light*, fashes when the
hazard light is activated.
m = Operating hour meter, counts
the operating hours while
the engine is running. All
maintenance work must be
performed according to the
indicated operating hours.
n = Fuel tank flling level.
No. 3 = Vents for air conditioning, heating
and ventilation, driver*
No. 4 = Vents for air conditioning, heating
and ventilation, footwell*
* Optional equipment
Section 3
3-6
4-2012
Fig. 10
No. 6 = Travel lever
Position
middle
= Braking position sevice brake
Position
middle, right
= Parking brake, to start the
engine
Position I = Forward travel
Position II = Backwards travel
Fig. 11
No. 7 = Rotary switch for vibration
Position
middle
= Vibration of
Position Right = low amplitude, high frequency
Position Left = high amplitude, low frequency
NOTE: If the engine speed drops under load
when driving on steep gradients, take the
travel lever slightly back towards neutral.
This relieves the hydraulic system and
reduces the load on the diesel engine.
Fig. 9
No. 5 = Push button for vibration
Select or actuate the frequencies with the
vibration selector switch.
Switch the vibration on or off by pressing the
push button.
3-7
Section 3
4-2012
Fig. 12
No. 8 = Rotary Switch for speed range
selection BW177 D-50
Position turtle = Working speed
Position rabbit = Transport speed
Fig. 13
No. 8 = Rotary Switch for speed range
selection BW177 DH-50/PDH-50
Position turtle = Working speed range on level
ground or on inclinations
steeper than 15%
Position rabbit,
low
= Working speed range on level
ground and on inclinations,
with high working speed
Position rabbit,
high
= Transport range, e.g. to drive
to the work location, vibration
not possible
Fig. 14
No. 9 = Emergency stop switch
The engine will be shut down and the brake will close.
Danger of accident!
Operate only in emergency situations
during operation, do not use as a service
brake.
The machine should only be started again after the
danger, that caused the actuation of the emergency
stop switch, has been removed.
For safety reasons the travel system of the machine will
only be enabled after the travel lever has been shifted
back to braking position.
operate = push the button completely
down, it will automatically lock
in end position.
unlock = turn the button clockwise and
release it.
to drive = move the travel lever frst to
braking position, then start the
engine and choose the travel
direction.
Section 3
3-8
4-2012
Fig. 15
No. 10 = Push button for warning horn
Fig. 16
No. 11= Fault warning light ASC Anti-Spin-
Control BW177 DH-50/PDH-50
NOTE: Further trouble shooting by means of
fashing codes on the ASC-control board in
the electric junction box.
Operation of the machine can be
continued, but you should inform the
after sales service of BOMAG.
Fig. 18
No. 15 = Rotary switch for working lights *
Position Left = Light of
Position Right = Working lights on, with
ignition switch in position I
Position Left = Light of
Position
Middle
= Sidelights on, with ignition
switch in position I or P
Position Right = Travel light on, with ignition
switch in position I.
Fig. 17
No. 14 = Rotary switch for light system
(StVZO)*
3-9
Section 3
4-2012
Fig. 20
No. 17 = Rotary momentary contact switch for
engine speed
Electric engine speed adjustment
NOTE: Normal position for engine start.
Turn anti-
clockwise
= Idle speed position
Turn clockwise = Full throttle position,
operating position for driving
and vibration
Fig. 19
No. 16 = Lever, steering wheel adjustment *
Danger of accident!
Do not adjust the steering wheel while
driving.
Pull up = Adjust height of steering
wheel
Press down = Adjust inclination of steering
wheel
* Optional equipment * Optional equipment
Always drive and vibrate with max.
engine speed! Control the travel speed
with the travel lever.
Fig. 21
Lever, swivelling of drivers seat *
Danger of accident!
Always lock the drivers seat in one of the
locking positions while driving.
Do not swivel the drivers seat while
driving.
NOTE: Swivelling angle max. 20 to either side.
Fig. 22
2-pole socket
Current only with the ignition switch in position I or
when the engine is running.
Swivel = Stop the machine and apply
the parking brake. Pull the
lever up and swivel the drivers
seat to the desired position.
Section 3
3-10
4-2012
** DASA = Data Collector
*** MESX = BMU-measuring technology control
** DASA = Data Collector
*** MESX = BMU-measuring technology control
Fig. 25
No. 20 = Fuses in electric installation box
BW177 DH-50/PDH-50
Fire hazard!
Do not use fuses with higher ampere
ratings and do not bridge fuses.
Fire hazard!
16 15 17 18 19 21 22 23 24 25 26 27
F
1
3
F
6
8
F
1
0
5
F
1
1
F
0
7
F
2
2
F
1
9
F
0
9
F
1
0
F
0
8
F
1
8
F
1
4
28 29 30 31 32 33 34 35 36
F
2
3
F
2
5
F
3
9
F
2
4
F
0
3
F
1
4
8
F
8
4
F
1
4
6
F
5
1
37
F
1
2
4
16 15 17 18 19 21 22 23 24 25 26 27
F
1
3
F
6
8
F
1
0
5
F
1
1
F
0
7
F
2
2
F
1
9
F
0
9
F
1
0
F
0
8
F
1
8
F
1
4
28 29 30 31 32 33 34 35 37
F
2
3
F
2
5
F
3
9
F
2
4
F
0
3
F
1
4
8
F
8
4
F
1
4
6
F
1
2
4
Fig. 24
No. 20 = Fuses in electric installation box
BW177 D-50
F13, 30A = Ignition switch
F68, 5A = Burglary protection*
F105, 20A = Engine speed
F11, 15A = Headlight front, StVZO*
F07, 15A = Hazard light, StVZO*
F22, 15A = Working lights rear*
F19, 15A = Working lights front*
F09, 15A = Parking and tail light L-H, StVZO*
F10, 15A = Parking and tail light R-H, StVZO*
F08, 15A = Directional indicators, StVZO*
F18, 10A = Working head lights, relay*
F14, 15A = Engine shutof of solenoid
F23, 10A = Signal horn
F25, 10A = Solenoid valve, neutral start and
backup horn
F39, 15A = Cab*
F24, 10A = Monitoring-module, indicators
F03, 15A = Vibration
F148, 10A = Controller MESX***
F124, 25A = Fuel-pre-heating*
F13, 30A = Ignition switch
F68, 5A = Burglary protection*
F105, 20A = Engine speed
F11, 15A = Headlight front, StVZO*
F07, 15A = Hazard light, StVZO*
F22, 15A = Working lights rear*
F19, 15A = Working lights front*
F09, 15A = Parking and tail light L-H, StVZO*
F10, 15A = Parking and tail light R-H, StVZO*
F08, 15A = Directional indicators, StVZO*
F18, 10A = Working head lights, relay*
F14, 15A = Engine shutof of solenoid
F23, 10A = Signal horn
F25, 10A = Solenoid valve, neutral start and
backup horn
F39, 15A = Cab*
F24, 10A = Monitoring-module, indicators
F03, 15A = Vibration
F51, 10A = Antispin Control (ASC)
F124, 25A = Fuel-pre-heating*
3-11
Section 3
4-2012
Fig. 26
a = toggle switch for flashing beacon*
b = toggle switch for front windscreen
wiper / washer*
c = toggle switch for rear windscreen
wiper/ washer
d = toggle switch for rear windscreen
heating*
Fig. 27
No. 21= Fuse box, cabin*
Up = Windscreen wiper moves to
end position and stops.
Down = Switches on wiping of front
windscreen.
Push button = Front windscreen is sprayed
during wiping.
Up = Windscreen wiper moves to
end position and stops.
Down = Switches on wiping of front
windscreen.
Push button = Rear windscreen is sprayed
during wiping.
Fire hazard!
Fig. 28
No. 22 = Control panel for cabin fan and AC*
(1), 15A = (F43) wiper/washer, rear*
(2), 15A = (F44) wiper/washer, front*
(3), 10A = (F130) relay for rear
windscreen heating, reading
light*
(4), 25A = (F31) cabin fan*
(5), 10A = (F41) fashing beacon*
(6), 15A = (F144) cab socket*
(7), 15A = (F143) rear windscreen
heating*
(8), 10A = (F42) potential 30, cab light*
e = Rotary switch for cabin ventilator*
Position 0 = Cabin ventilator switched of.
Position 1, 2
and 3
= Ventilator stages of diferent
strengths
f = Rotary switch for Air Conditioning
Temperature*
Position 0 = Cabin AC switched of.
Postion blue
range
= Temperature selection for air
conditioning.
Section 3
3-12
4-2012
Fig. 30
No. 24 = Cabin light*
i = reading and dashboard light*
j = toggle switch for reading and
dashboard light*
k = toggle switch for cabin light*
l= cabinlight*
Fig. 31
No. 25 = Main fuse for battery and Grid Heater
Note: Battery with main fuse is located on the
side of the BW177-50
125A = (F00) Main Fuse (Inner Fuse)
125A = (F48) Glow Plugs (Outer Fuse)
Fig. 29
No. 23 = Heat Temperature Control
g = Rotary switch for cabin heater
(temperature selector switch)*
Position 0 = Cabin heater switched of.
Position red
range
= Temperature selection for
cabin heater.
4-1
Section 4
OPERATION
4-2012
TABLE OF CONTENTS
PAGE
GENERAL NOTES ........................................................................................................................... 3
TESTS BEFORE STARTING TO OPERATE ...................................................................................... 3
STARTING THE ENGINE ................................................................................................................. 5
STARTING WITH JUMP WIRES ...................................................................................................... 7
DRIVING THE MACHINE ................................................................................................................ 7
SWITCHING THE VIBRATION ON AND OFF ................................................................................. 9
SWITCH THE VIBRATION ON ................................................................................................... 10
SWITCHING THE VIBRATION OFF .......................................................................................... 10
OPERATING THE PARKING BRAKE, STOPPING THE MACHINE ............................................... 11
SHUTTING THE ENGINE DOWN ................................................................................................. 12
EMERGENCY EXIT ........................................................................................................................ 13
ADJUSTING THE STEERING WHEEL ........................................................................................... 13
ADJUSTING THE SEAT ................................................................................................................. 14
ADJUSTING THE OPTIONAL SEAT ............................................................................................. 14
OPERATING THE HOOD .............................................................................................................. 15
BOTTOM POSITION .................................................................................................................. 15
TOP POSITION ......................................................................................................................... 15
TOWING IN CASE OF AN ENGINE FAILURE BW177 D-50 ......................................................... 16
TOWING IN CASE OF AN ENGINE FAILURE BW177 DH/PDH-50 ............................................. 18
AFTER TOWING ......................................................................................................................... 19
TRANSPORT ................................................................................................................................. 20
Section 4
OPERATION
4-2 4-2012
4-3
Section 4
OPERATION
4-2012
Please read section 3 Indicators and Control Elements
thoroughly before operating the machine if you are
not yet fully familiar with the indicators and control
elements of the machine.
All indicators and control elements are described in
detail in this chapter.
General notes
The following tests must be performed before each
work day or before a longer work period.
Danger of accident!
Please observe strictly the safety
regulations in chapter 2 of these
oper at i ng and mai nt enanc e
instructions!
Park the machine on level ground.
Check:
Fuel tank and fuel lines for leaks
Bolted connections for tight fit
Function of the steering
Check the machine for cleanliness and damage
Availability of the appropriate operating and
maintenance instructions,
Check if the machine has been properly serviced.
NOTE: For a description of the following work
refer to the section maintenance every 10
operating hours
Engine oil level
NOTE: Hydraulic systems, which are flled with
Panolin HLP Synth. 46, the same oil must
be used for flling up. In case of any other
ester based oil consult the lubrication
service department of the respective oil
manufacturer.*
Check the hydraulic oil level, top up if necessary.
Check the coolant level, top up if necessary.
Fire hazard!
Do not refuel in closed rooms
Check the fuel level, top up if necessary.
Check water separator in the fuel system, drain if
necessary.
Tests before starting to operate
Section 4
OPERATION
4-4 4-2012
Adjust the scrapers if necessary
Tire pressure. Pressure see technical data.
Ensure equal pressure in both tires.
Fig. 35
Check, whether the emergency stop switch (Fig.
35) is unlocked.
Fig. 36
Turn rotary switch (Fig. 36) to position Min (idle
speed).
Fig. 37
Turn the ignition key (Fig. 37) to position I.
4-5
Section 4
OPERATION
4-2012
Danger of accident!
Always wear your seat belt.
Fig. 33
Check, whether the travel lever (Fig. 33) is
engaged to the right in brake position.
Fig. 34
Turn the rotary vibration selector switch (Fig. 34)
to position 0, vibration off.
Starting the engine
Section 4
OPERATION
4-6 4-2012
Fig. 39
Five [5] position switch is used to start engine and turn
electrical systems of. (Fig 39)
Turn the ignition key to position III (Fig. 39), the
starter will crank the engine.
As soon as the engine ignites return the ignition
key to position I.
The ignition switch is provided with a lock against
repetitive starting. To repeat the starting procedure
you must frst turn the ignition switch back to the 0
position.
NOTE: The engine can only be started if the
travel lever is in neutral.
Do not allow the engine to run longer
than 10 minutes with idle speed.
Fig. 38
All control and warning lights (Fig. 38) in the fault
monitoring board light up for a moment.
The battery control (d) and brake warning lights (g) light
up, the engine oil pressure warning light (b) fashes.
Cold Weather Starting BW177D/DH/PDH-50
The BW177D/DH/PDH-50 is equipped with a automatic
cold weather assist starting system. This consisted of
a glow plug attached to the engine. When the key is
turned to the I position during cold weather the glow
plug lamp will continue to be illuminated after the
majority of the other lamps have turned of. WAIT until
the grid heater lamp turns of before attempting to start
the engine. The amount of time for the grid heater
lamp to turn of is dependent on the temperature at
the sensor.
Per f or m t he st ar t i ng process
for maximum 20 seconds without
interruption and pause for a minute
between starting attempts.
If the engine has not started after two
attempts perform trouble shooting.
4-7
Section 4
OPERATION
4-2012
Fig. 40
A wrong connection will cause severe
damage in the electric system.
Bridge the machine only with a 12 Volt auxiliary
battery.
When jump starting with an external battery
connect both plus poles first.
Then connect the ground cable first to the minus
pole of the current supplying auxiliary battery
and then to engine or chassis ground, as far away
from the battery as possible (Fig. 40).
Start as described under Starting the engine.
Once the engine is running switch on a powerful
consumer (working light, etc.).
If no powerful consumer is switched
on voltage peaks may occur when
separating the connecting cables
between the batteries, which could
damage electrical components.
After starting disconnect the negative poles
(ground cable) first and the positive poles after.
Switch off the consumer
Starting with jump wires
Danger of accident!
Wet and loose soils considerably reduce
the ground adhesion of the machine on
inclinations and slopes.
Soil conditions and weather infuences
impair the gradability of the machine.
Do not drive up and down inclinations
exceeding the maximum gradability of
the machine (see technical data).
Do not drive without wearing your seat
belt.
Always give way to loaded transport
vehicles! Before starting to drive make
sure that the drive range is absolutely
safe.
Always keep the cabin door closed
while driving with the machine. With
the door opened and the machine fully
articulated extreme oscillations of the
machine may damage the door.
Driving the machine
Section 4
OPERATION
4-8 4-2012
Fig. 41
Close the cabin door (Fig. 41).
Fig. 42
Fasten your seat belt (Fig. 42).
Start engine, see previous sections.
Fig. 43
Select the desired travel speed range (Fig. 43).
BW177 D-50
Fig. 44
BW177 DH/PDH-50
Fig. 45
Turn the rotary switch (Fig. 45) to Max position
(full throttle).
Fig. 46
Push the travel lever (Fig. 46) to the left out
of braking position and move it slowly to the
desired travel direction.
4-9
Section 4
OPERATION
4-2012
Risk of damage!
When compacting with vibration
you must check the efect of nearby
buildings and underground supply lines
(gas, water, sewage, electric power),
if necessary stop compaction with
vibration.
Do not activate the vibration on hard
(frozen, concrete) ground. Danger of
bearing damage!
Fig. 48
Switch to working speed (Fig. 48) (turtle).
BW177 DH-50/PDH-50.
NOTE: Shift the travel lever out of 0- position
slowly to forward or reverse, the machine
will drive forward or reverse at a speed
which corresponds with the displacement
of the travel lever.
Returning the travel lever towards neutral
will brake the machine and in 0- position
of the travel lever the machine will stop.
Danger of accident!
When stopping on inclinations and
slopes pull the travel lever to the right
and lock it in braking position.
Important notes on travel operation
When changing the travel direction
hold the travel lever for a moment in
0- position, until the machine has
stopped, before actuating to the new
travel direction.
Do not operate jerkily!
When driving up and down inclinations
move the travel lever slowly back
towards neutral to brake the machine.
If the engine speed drops when driving
up extreme inclinations move the ravel
lever slightly back, if necessary change
to the lower speed range.
Switching the vibration on and of
Fig. 47
BW177 D-50
Section 4
OPERATION
4-10 4-2012
Pre-selecting the vibration
Fig. 49
Pre-select amplitude/frequency with the rotary
switch (Fig. 49).
Switch the vibration on
Fig. 50
Turn the rotary switch (Fig. 50) to position Max
(full throttle).
Switch the vibration on only at max.
engine speed.
Fig. 51
Press the push button (Fig. 51) in the travel lever
while driving, the drum will vibrate.
Switching the vibration of
Press the push button again and after work
switch the rotary vibration switch to position 0.
4-11
Section 4
OPERATION
4-2012
Fig. 52
Return the travel lever (Fig. 52) slowly to neutral
-position and engage it to the right parking brake
position.
Operating the parking brake, stopping the
machine
The machine is automatically braked by the hydrostatic
drive and parking brake closes.
NOTE: The parking brake also closes
automatically when shutting the engine
down.
Section 4
OPERATION
4-12 4-2012
Straighten the articulated joint to
provide easier access to the machine.
Fig. 53
Return the travel lever (Fig. 53) slowly to
neutral- position and engage it to the right in
braking position.
Fig. 54
Turn rotary switch (Fig. 54) to position Min (idle
speed).
NOTE: Do not shut the engine down all of the
sudden from full speed, but let it idle for a
while for temperature equalization.
Fig. 55
Turn the ignition switch (Fig. 55) to position 0
or P and pull the ignition key out.
NOTE: The parking brake closes automatically
when shutting the engine down.
Danger of accident!
Secur e t he machi ne agai ns t
unauthorized use, pull the ignition
key out, lock the cabin door.
Shutting the engine down
4-13
Section 4
OPERATION
4-2012
If the machine should turn over and the cabin door is
closed, the right hand side cabin window can be used
as an emergency exit.
Fig. 56
Adjustment of steering wheel in height, pull lever
(Fig. 56) up and move the steering wheel to the
desired height.
Adjustment of steering wheel inclination, press
lever down and adjust the inclination of the
steering wheel.
Danger of accident!
After the adjustment make sure that the
steering wheel adjustment is securely
locked in place.
Emergency exit Adjusting the steering wheel*
Section 4
OPERATION
4-14 4-2012
Danger of accident!
Do not adjust the seat while driving.
Fig. 57a
To adjust the seat in longitudinal direction
disengage the lever 1 (Fig. 57) and slide the seat
forward or back.
To adjust the weight actuate the lever (3)
(Fig. 57a).
To adjust the inclination of the backrest actuate
the lever (2) (Fig. 57a) and tilt the backrest
forward or back.
Adjusting the seat Adjusting the optional seat *
Fig. 58
To adjust the seat in longitudinal direction dis-
engage lever e (Fig. 58) upwards and push the
seat forward or back.
To adjust the weight turn lever (d) and read the
weight in sight glass (c).
To adjust the inclination of the backrest oper-ate
lever (a) and tilt the backrest forward or back.
To swivel the seat pull lever (b) up and turn the
seat to the desired direction.
Fig. 59
To adjust the height of the seat lift the seat up
(Fig. 59) until it engages at the desired level.
When lifting the seat completely it will sink down to
lowest position.
Fig. 57
4-15
Section 4
OPERATION
4-2012
Fig. 60
Unlock the lock (Fig. 60).
To open the hood press in the button and turn
the handle.
Danger of accident!
If the hood needs to be opened further
for maintenance or repair work,
support it safely.
Bottom position
Fig. 61
Pull the support out of the bracket and support
the hood (Fig. 61).
Top position
Push the hood to top position.
Operating the hood
Fig. 62
Pull the spring pin (Fig. 62) out of the bracket.
Secure the hood in the protection tube with
spring plug.
Section 4
OPERATION
4-16 4-2012
Fig. 65
To release the brake turn counter nuts 1 (Fig. 66)
approx. 8 mm back.
Turn the brake releasing screws (2) completely in
against the stop
From this stop turn the screw in for
maximum another turn to release the
brake!
Turn the screws in evenly on both sides.
Turn the screws in alternately for 14 turn at a
time.
Repeat this procedure on the opposite
wheelside.
Fig. 64
Slacken the counter nuts on the spindles of both
high pressure relief valves (Fig. 63) to create a by-
pass around the travel pump.
Turn the threaded spindle in until it is flush with
the nut.
Retighten the counter nut.
Do not turn the valves out completely.
Secure the machine with wheel chocks
against unintentional rolling.
Danger of accident!
When using towing ropes tow the
machine only uphill.
When towing downhill you must use a
rigid towing device.
The machine cannot be steered.
Secure the machine with wheel chocks against
unintentional rolling.
Fig. 63
Attach chains (Fig. 63) or towing ropes to the
lifting hooks.
Towing speed 1 km/h, max. towing
distance 500 m.
Open the tailgate.
Towing in case of an engine failure
BW177 D-50
4-17
Section 4
OPERATION
4-2012
Fig. 66
Remove plug 1 (Fig. 66).
Place an U-section (4) across the brake housing
(2) and turn the screw (5) into the tapped bore
(3), untilit bottoms.
Turn the nut (6) down and tightenit approx. one
revolution. The drum must rotate freely.
Section 4
OPERATION
4-18 4-2012
Secure the machine with wheel chocks
against unintentional rolling.
Danger of accident!
When using towing ropes tow the
machine only uphill.
When towing downhill you must use a
rigid towing device.
The machine cannot be steered.
Secure the machine with wheel chocks against
Fig. 69
Attach chains (Fig. 69) or towing ropes to the
lifting hooks.
Towing speed 1 km/h, max. towing
distance 500 m.
Open the tailgate.
Towing in case of an engine failure
BW177 DH/PDH-50
Fig. 71
To release the brake turn counter nuts 1 (Fig. 71)
approx. 8 mm back.
Turn the brake releasing screws (2) completely in
against the stop
From this stop turn the screw in for
maximum another turn to release the
brake!
Turn the screws in evenly on both sides.
Turn the screws in alternately for 14 turn at a
time.
Repeat this procedure on the opposite
wheelside.
Fig. 70
Slacken the counter nuts on the spindles of both
high pressure relief valves (Fig. 70) to create a by-
pass around the travel pump.
Turn the threaded spindle in until it is flush with
the nut.
Retighten the counter nut.
Do not turn the valves out completely.
4-19
Section 4
OPERATION
4-2012
Fig. 72
Press the emergency operation button (Fig. 72)
completely down.
NOTE: Use a suitable pipe.
After starting the engine the emergency
operation button returns automatically to
initial position.
Insert the owner supplied pump lever and
operate the pump, until the brakes in the axle
and drum are released.
After towing
Before detaching the tow bar block
the machine with chocks to prevent
unintended rolling.
Turn the threaded spindle of the high pressure
relief valves completely out again and tighten the
counter nuts.
Turn all brake releasing screws of the axle evenly
back out, until they are light moving again.
Fig. 74
Unscrew the brake releasing screws (Fig. 74) for
two turns and tighten the counter nuts.
Repeat this adjustment procedure on the
opposite wheel side.
NOTE: If necessary replace the seal ring under
the counter nut if it is leaking.
For this purpose completely unscrew the
brake releasing screw, replace the seal
ring and lubricate the screw with silicone
grease.
Reinstall the screw with a new seal ring
and adjust the protrusion as described
above.
Fig. 73
Turn the brake releasing screws (Fig. 73) back in
again, until they abut against the brake piston.
Section 4
OPERATION
4-20 4-2012
Fig. 77
Lash the machine on the transport vehicle (Fig.
77), use the four lashing eyes on front and rear
frame for this purpose.
Support the front frame to avoid overstressing of
the rubber buffers.
Fig. 78
For lifting use also the four lifting eyes (Fig. 78)
and appropriate lifting gear.
Fig. 75
Pull the spring pin (Fig. 75) out.
Engage the articulation lock and secure it with
the spring pin.
Fig. 76
Engage the articulation lock and secure it with
the spring pin (Fig. 76).
Danger of accident!
Use only stable loading ramps of
sufcient load bearing capacity. Make
sure that persons are not endangered
by the machine tipping or sliding of.
Lash the machine down, so that it is
secured against rolling, sliding and
turning over.
Do not stand or step under loads being
lifted. Always use shackles on the lifting
points for loading, tying or lifting the
machine.
Transport
4-21
Section 4
OPERATION
4-2012
Operating the optional Dozer Blade *
Machine L H
BW 177 990180mm
(39.07.0in)
80080mm
(31.53.1in)
Fig. 79
Position of centre of gravity (Fig. 79).
NOTE: The tolerances account for all possible
options, such as cabin, additional weight
etc.
Weights: See technical data.
Danger of accident!
The machine cannot be steered if the articulation
lock is applied.
After transport release the articulation lock again
and store it in the receptacle.
Fig. 61
Lift or lower the dozer blade by means of the
pedal (Fig. 61).
Do not use the dozer blade to transport
per-sons. Danger to life!
Moving other vehicles with the dozer
blade is prohibited!
NOTE: Always lower the dozer blade to the
ground before shutting the engine down.
Dozer Blade inoperable at low idle.
Position I = lifting the dozer blade Position
Position 0 = neutral position, the pedals
returns automatically to
0-position
Position II = lowering the dozer blade Position
Position III = foat position, for levelling the soil
during reverse travel.
Section 4
OPERATION
4-22 4-2012
NOTES
5-1
Section 5
MAINTENANCE
4-2012
TABLE OF CONTENTS
PAGE
GENERAL NOTES ON MAINTENANCE ......................................................................................... 5
NOTES ON THE FUEL SYSTEM .................................................................................................. 5
NOTES ON THE ENGINE PERFORMANCE ................................................................................. 5
NOTES ON THE HYDRAULIC SYSTEM ...................................................................................... 5
NOTES ON THE COOLING SYSTEM ........................................................................................... 6
FUELS AND LUBRICANTS ............................................................................................................. 6
ENGINE OIL ................................................................................................................................ 6
OIL CHANGE INTERVALS .......................................................................................................... 7
FUELS ............................................................................................................................................. 7
FUEL QUALITY ........................................................................................................................... 7
WINTER FUEL .............................................................................................................................. 7
OIL FOR DRIVE AXLE .................................................................................................................... 8
LUBRICATION GREASE ................................................................................................................. 8
HYDRAULIC OIL ............................................................................................................................ 8
BIO-DEGRADABLE HYDRAULIC OIL ........................................................................................ 8
COOLANT, ANTI-FREEZE AGENT ................................................................................................. 9
TABLE OF FUELS AND LUBRICANTS .......................................................................................... 10
RUNNING-IN INSTRUCTIONS ..................................................................................................... 11
MAINTENANCE CHART ............................................................................................................... 12
CHECK THE ENGINE OIL LEVEL .................................................................................................. 14
CHECK, CLEAN THE WATER SEPARATOR ................................................................................... 14
CHECKING THE FUEL LEVEL ....................................................................................................... 15
Section 5
MAINTENANCE
5-2 4-2012
CHECKING THE COOLANT LEVEL .............................................................................................. 16
CHECKING THE HYDRAULIC OIL LEVEL .................................................................................... 16
CHECKING THE V-BELT ...................................................................................................... 17
CHECKING THE TIRE PRESSURE ................................................................................................. 17
ADJUSTING THE SCRAPERS ....................................................................................................... 18
CHANGING ENGINE OIL AND OIL FILTER CARTRIDGES .......................................................... 19
CLEAN THE COOLING FINS ON ENGINE AND HYDRAULIC OIL COOLER ............................... 21
CHECK THE OIL LEVEL IN THE DRIVE AXLE .............................................................................. 22
CHECKING THE OIL LEVEL IN THE LEFT/RIGHT HAND PLANETARY DRIVES ........................ 22
CHECKING THE OIL LEVEL IN THE ............................................................................................. 23
VIBRATION BEARING .................................................................................................................. 23
CHECKING THE OIL LEVEL IN THE ............................................................................................. 23
DRUM DRIVE GEAR ..................................................................................................................... 23
SERVICE THE BATTERY ............................................................................................................... 24
DRAINING THE FUEL TANK SLUDGE ......................................................................................... 25
CHANGE THE FUEL FILTER CARTRIDGE .................................................................................... 26
CHANGE THE FUEL PRE-FILTER CARTRIDGE ............................................................................ 27
CHECK CONDITION AND TENSION OF REFRIGERANT (OPTIONAL) COMPRESSOR V-BELT,
REPLACE THE V-BELT .................................................................................................................. 29
CHANGE THE OIL IN THE DRIVE AXLE ....................................................................................... 30
CHANGE THE OIL IN THE PLANETARY DRIVE ........................................................................... 31
CHANGE THE OIL IN THE DRUM DRIVE GEAR .......................................................................... 32
CHANGING THE OIL IN THE VIBRATION BEARINGS ................................................................. 33
CHECKING THE FASTENING ELEMENTS ON THE ENGINE ....................................................... 34
5-3
Section 5
MAINTENANCE
4-2012
RETIGHTEN THE FASTENING OF THE AXLE ON THE FRAME ................................................... 34
TIGHTENING THE WHEEL NUTS ................................................................................................. 35
CHECKING THE ROPS .................................................................................................................. 35
CHECKING, ADJUSTING THE VALVE CLEARANCE .................................................................... 36
CHANGING THE HYDRAULIC OIL AND THE BREATHER FILTER .............................................. 39
CHANGING THE HYDRAULIC OIL FILTER .................................................................................. 40
CHANGING THE COOLANT ......................................................................................................... 41
CLEANING, CHANGING THE DRY AIR FILTER CARTRIDGE ...................................................... 43
BLEEDING THE FUEL SYSTEM .................................................................................................... 46
ADJUSTING THE PARKING BRAKE ............................................................................................. 47
CHANGING THE TIRES................................................................................................................. 48
CHANGING THE FRESH AIR FILTER IN THE CABIN ................................................................... 48
TIGHTENING TORQUES .............................................................................................................. 49
ENGINE CONSERVATION ............................................................................................................ 49
Section 5
MAINTENANCE
5-4 4-2012
5-5
Section 5
MAINTENANCE
4-2012
General notes on maintenance
When servicing the machine pay careful attention to
all applicable safety instructions.
Thorough maintenance of the machine ensures
maximum reliability and prolongs the lifetime of
important components. The necessary effort can
by no means be compared with the problems and
malfunctions that could occur if this is not observed.
The terms left/right are always related to travel direction
forward.
Clean machine and engine thoroughly before
starting maintenance work.
For maintenance work park the machine on level
ground.
Maintenance work must generally be carried out
with the engine shut down.
Depressurize hydraulic lines before working on
them.
Disconnect the battery and cover it with
insulation material before starting to work on
electrical components.
Always attach the articulation lock (transport
lock) before starting to work in the articulation
area of the machine.
Catch running out oils, coolant and fuel and do not let
them seep into the ground or into the sewage system.
Dispose of oils, coolant and fuels environmentally.
Notes on the fuel system
The lifetime of the diesel engine is decisively depending
on the cleanliness of the fuel.
Keep the engine free of dirt and water as this
could damage the injection elements of the
egine.
Zinc lined drums are not suitable for storing fuel.
The fuel drum should rest for a longer period of
time before drawing off fuel.
Do not let the suction hose disturb the sludge on
the bottom of the drum.
Do not draw off fuel from near the bottom of the
fuel drum.
Fuel left in the fuel drum is not suitable for the
engine and should only be used for cleaning
puposes.
Notes on the engine performance
Combustion air and fuel injection rates of the diesel
engine have been carefully adjusted and determine
the engines performance and temperature level as well
as the quality of the exhaust gas. If your machine has
to operate permanently in thin air (at high altitudes)
and with full power, you should consult the after sales
service of BOMAG or the service department of the
engine manufacturer.
Notes on the hydraulic system
During maintenance work in the hydraulic system
cleanliness is of utmost importance. Make sure that
no dirt or other impurities can enter into the system.
Small particles can fute valves, cause pumps to seize
and block restrictors and pilot bores, thereby causing
costly repairs.
If during the daily oil level check the oil level is
found to have dropped, check all lines, hoses and
components for leakages.
Seal external leaks immediately. If necessary
inform the responsible service department.
Do not store drums with hydraulic oil outside, or
at least keep them under a cover. During weather
changes water may penetrate through the
bunghole.
Always fill the hydraulic system using the filling
and filtering unit (BOMAG part-no. 007 610 01).
This unit is equipped with a fine filter, which
filters the hydraulic oil and prolongs the lifetime
of the system filter.
Clean fittings, filler caps and their immediate
surrounding area before removing them, so that
no dirt can fall in.
Do not leave the tank opening unnecessarily
open, cover it so that no dirt can fall in.
Environment
Section 5
MAINTENANCE
5-6 4-2012
Fuels and lubricants
Notes on the cooling system
On water cooled engines the preparation and
monitoring of the coolant is of utmost importance, as
otherwise engine failures caused by corrosion, caviation
and freezing may occur.
The coolant is a mixture of water and a cooling system
protection agent.
The cooling system must be permanently monitored.
Apart from the coolant level inspection this includes
also the inspection of the concentration of cooling
system protection agent.
The concentration of the cooling system protection
agent can be checked with commercially available test
instruments (glycomat).
Health hazard!
The mixing of nitride based cooling
system protectionagents with amine
based agents will cause the generation
of highly toxic nitrosamines.
Cooling system protection agents must be disposed
of environmentally.
Engine oil
Oil quality
Lubrication oils are classified according to their
performance and quality class. Oils according to other
comparable specifcations may be used.
The exact assignment of the approved oil qualities and
oil change intervals can be taken from the following
section Lubrication oil change intervals.
Consult your local service station if in doubt.
Oil viscosity
Multi-purpose oils should be generally used.
Since lubrication oil changes its viscosity with the
temperature, the ambient temperature at the operating
location of the engine is of utmost importance when
choosing the viscosity class (SAE-class) .
Optimal operating conditions can be achieved by using
the opposite oil viscosity chart (Fig. 93) as a reference.
Occasionally falling short of the temperature limits will
impair the cold starting ability, but will not cause any
engine damage. In order to keep the occurring wear
as low as possible, occassional exceeding of the limits
should not happen over a longer period of time.
Environment
Approved engine oils
Cummins Engine
Standard Classifcations
(CES)
American Petroleum
Institute Classifcation
(API)
International
Classifcations
Comments
N/A API CD, API CE,
API CG-4/SH
ACEA E-1 OBSOLETE DO NOT USE
CES-20075 API CF-4/SG ACEA E-2, ACEA E-3,
JAMA DH-1
Minimum acceptable oil
classifcation for Midrange
engines.
CES-20071, CES-20076 API CH-4/SJ, API CH-4 Global DHD-1 Acceptable oil
classifcation for Midrange
engines
CES-20072, CES-20077 API CH-4 ACEA E-5, Global DHD-1 Similiar in performance to
CES-20071 but validated
under European test
standards. Excellent oil for
midrange engines
CES-20078 API CI-4/SK, API CI-4 N/A Excellent oil for midrange
engines
5-7
Section 5
MAINTENANCE
4-2012
Fig. 93
With their better temperature and oxidation stability
synthetic lubrication oils ofer quite a few benefts.
Oil change intervals
The longest permissible time a lubrication oil should
remain in an engine is 1 year. If the following oil change
intervals are not reached over a period of 1 year, the
oil change should be performed at least once per year,
irrespective of the operating hours reached.
* European Engine Oil Sequences
** American Petroleum Institute
Fuels
Fuel quality
You should only use commercially available brand
diesel fuel with a sulphur content below 0.5% (5000
ppm)
1
and ensure strict cleanliness when flling in.
Use only winter-grade diesel fuel under low ambient
temperatures. The fuel level should always be topped
up in due time so that the fuel tank is never run dry,
as otherwise flter and injection lines need to be bled.
Cummins Inc. recommends that the cetane number
of diesel fuel be a minimum of 45 for engines that are
expected to operate at temperatures below 0C [32F]
and a minimum of 42 for engines that are operated at
temperatures above 0C [32F].
Using diesel fuel with lower than recommended
cetane number can cause hard starting, instability,
and excessive white smoke. To maintain satisfactory
operation at low ambient temperatures, it is important
to specify diesel fuel of the correct cetane number.
Cummins Inc. recommends the use of ASTM number
2D fuel. The use of number 2D diesel fuel will result
in optimum engine performance. At operating
temperatures below 0C [32F], acceptable performance
can be obtained by using blends of number 2D and
number 1D.
For a list of acceptable substitute fuels contact the
engine manufacturer.
Winter fuel
Fire hazard!
Diesel fuels must never be mixed with
gasoline.
For winter operation use only winter diesel fuel, to avoid
clogging because of parafn separation. At very low
temperatures disturbing parafn separation can also
be expected when using winter diesel fuel.
These intervals apply only when using a
diesel fuel with maximum 0.5 % sulphur
by weight and for ambient temperatures
higher than -10 C.
ACEA*

E-5
E-7
= 500 operating hours
API**
CH-4/SJ
CI-4/SK
= 500 operating hours
1. Regional, national, or international regulations can require lower
sulfur content. U.S. EPA and California regulations for model year 2011
and later non-road diesel engines require use of low sulfur diesel fuel
(LSD) with 500 ppm maximum or ultra low sulfur diesel fuel (ULSD)
with 15 ppm maximum.
Section 5
MAINTENANCE
5-8 4-2012
In most cases a sufcient cold resistance can also be
achieved by adding fow enhancing fuel additives.
Consult the engine manufacturer.
BioDiesel
Due to the extreme quality diferences of bio-diesel fuels
available on the market, BOMAG recommends that the
use of biodiesel fuels be done in strict accordance with
engine manufactures guidelines. Refer to the engine
manufactures operation, maintenance and service
manuals for certifed fuel usage and specifcations.
Oil for drive axle
For the drive axle use only multi-purpose transmission
oil of API-class GL5 with viscosity class SAE 90.
The additives in this oil ensure low wear lubrication
under all operating conditions.
Lubrication grease
For lubrication use only EP-high pressure grease, lithium
saponifed (penetration 2).
Hydraulic oil
The hydraulic system is operated with hydraulic oil HV
46 (ISO) with a kinematic viscosity of 46 mm2/s (cSt)
at 40C. For topping up or for oil changes use only
high-quality hydraulic oil, type HVLP according to DIN
51524, part 3, or hydraulic oils type HV according to ISO
6743/3. The viscosity index (VI) should be at least 150
(observe information of manufacturer).
OR
The hydraulic system is operated with hydraulic oil
similar to an ISO VG68 but with a kinematic viscosity
of 60 mm2/s (cSt) at 40C. For topping up or for oil
changes use only high-quality hydraulic oil, of type
Multipurpose Tractor Lubricant similar to a Mobil 424
or CITGO Trans Guard. The viscosity index (VI) should
be at least 140 (observe information of manufacturer).
Bio-degradable hydraulic oil
On request the hydraulic system can also be flled with
ester based biodegradable hydraulic oil (Panolin HLP
Synth. 46). The biologically quickly degradable hydraulic
oil meets all demands of a mineral oil based hydraulic
oil according to DIN 51524.
In hydraulic systems flled with Panolin HLP Synth.
46 always use the same oil to top up. When changing
from mineral oil based hydraulic oil to an ester based
biologically degradable oil, you should consult the
lubrication oil service of the oil manufacturer for details.
Check the flter more frequently after this change.
Oil change biodegradable hydraulic oil:
Perform regular oil analyses for content
of water and mineral oil.
Replace the hydraulic oil flter element
every 500 operating hours.
5-9
Section 5
MAINTENANCE
4-2012
Coolant, anti-freeze agent
Use only soft tap water (drinking water) to prepare the
coolant mix.
As a protection against frost, corrosion and boiling
point anti-freeze agents must be used under any
climatic conditions.
The proportion of cooling system protection agent
must be between min. 35% and max. 45% to the water.
Do not mix different coolants and
additives of any other kind.
of environmentally.
Coolant
As a protection against frost, corrosion and boiling
point anti-freeze agents must be used under any
climatic conditions.
Do not mix different coolants and
additives of any other kind.
If no cooling system protection agent
is available in tropical zones, you may
also use a corrosion protection agent
(CUMMINS Liquid DCA).
Do not mix in more than 50% cooling
system protection agent, except when
a lower frost protection is required.
However, the proportion of cooling
system protection agent should never
exceed 68%. A higher concentrations
the frost protection efect drops again.
Use only soft tap water (drinking water)
to prepare the coolant mix.
The water should not contain more than
100 ppm of sulphates (SO
4
) or 40 ppm
of chlorides (CL).
The cool i ng syst em must be
permanently monitored. Besides
the inspection of the coolant level
this includes also the inspection of
the concentration of cooling system
protection agent.
The concentration of cooling system
protection agent must be checked with
a refractometer (Fleetguard part-no.
C2800). Other measuring equipment
is not suitable for high-performance
diesel engines.
Coolant must be changed every two
years. Anti-freeze concentration
Ethylene Glycol
40 % = -23 C (-10 F)
50 % = -34 C (-34 F)
60 % = -54 C (-65 F)
68 % = -71 C (-90 F)
Propylene Glycol
40 % = -21 C (-6 F)
50 % = -33 C (-27 F)
60 % = -49 C (-56 F)
of environmentally.
Specifcation for cooling system protection agent
ASTM 4958 (GM6038M)
Environment
Environment
Section 5
MAINTENANCE
5-10 4-2012
Table of fuels and lubricants
Assembly Fuel or lubricant Quantity approx.
Summer Winter Attention:
Observe the level marks
Engine Engine oil
API CH-4/SJ, CI-4/SK
or
ACEA: E5,E7
approx. 8.5 litres,
(9.0 qt) without oil flter
SAE 10W/40
-4F to +104F
(-20 C to +40 C)
SAE 15W/40
+5F to +104F
(-15 C to +40 C)
Fuel
Diesel Winter diesel fuel approx. 150 litres (39.6 gal)
Hydraulic oil
(ISO), HV 46, kinem.
viscosity 46 mm
2
/s (cSt) at 40 C
viscosity index greater than 150
or
Similar to an ISO VG68
60mm
2
/s (cSt)at 40 C
viscosity index greater than 140
approx. 60 litres (15.8 gal)
Vibration bearings Engine oil SAE 15W/40 approx. 3.2 litres (3.4 qt)
Drive axle Gear oil SAE 90, API GL5 approx. 7.3 litres (7.7 qt)
Wheel hubs Gear oil SAE 90, API GL5 approx. .75 litres (0.8 qt)
Gear Box Drum Drive
(DH/PDH Only)
Gear oil SAE 90, API GL5 approx. 2.5 litres (2.6 qt)
Air conditioning system Refrigerant R134A approx. 1400 g (3.8 lb)
Engine cooling system Cooling system protection agent approx. 16 litres (16.9 qt)
5-11
Section 5
MAINTENANCE
4-2012
Running-in instructions
The following maintenance work must be performed
when running in new machines or overhauled
engines:
Up to approx. 250 operating hours check
the engine oil level twice every day.
Depending on the load the engine is
subjected to, the oil consumption will
drop to the normal level after approx.
100 to 250 operating hours.
After a running-in time of 30 minutes
Retighten the V-belt
After 250 operating hours
Retighten bolted connections on intake and
exhaust tubes, oil sump and engine mounts.
Retighten the bolted connections on the
machine.
Retighten all wheel fastening screws with the
specified tightening torque.
Changing engine oil and oil filter
1. Oil change vibration bearings
Oil change in drive axle
Oil change in wheel hubs
2. Oil change vibration bearings
Oil change drum drive gear (only DH and PDH
machines)
Ajusting the valve clearance
Section 5
MAINTENANCE
5-12 4-2012
With all maintenance intervals perform also the work
for shorter preceding service intervals.
Designation Note
Every 10 operating hours
Check the engine oil level
Checking, cleaning the water separator
Check the fuel level
Check the coolant level
Check the hydraulic oil level
Checking the V-belt
Dipstick mark
Inspection glass
Check the tire pressure
Adjust the scrapers
see technical data
Clean the cooling fns on engine and hydraulic oil cooler
Check the oil level in the drive axle
Check the oil level in the planetary gears
Check the oil level in the vibration bearings
Check the oil level in the drum drive gear
min. 1x per year
DH and PDH machines
Changing engine oil and oil flter cartridge
Servicing the battery
Drain the sludge from the fuel tank
Change the fuel flter cartridge
Changing the fuel pre-flter cartridge
Checking V-belt tension, idler pulley and fan hub
min. 1x per year
distilled water, pole grease
Maintenance chart
5-13
Section 5
MAINTENANCE
4-2012
Designation Note
Change the oil in the drive axle
Change the oil in the planetary gears
Changing the oil in the drum drive gear
Change the oil in the vibration bearings
Check the engine mounts
Check the fastening of the axle on the frame
Tighten the wheel nuts
Check the ROPS
min. 1x per year
min. 1x per year
DH and PDH machines, at least 1x per
year min. 1x per year
Check, adjust the valve clearance

Changing hydraulic oil and breather flter*
Changing the hydraulic oil flter*
Change the coolant
Intake = 0,35 mm (0,014IN), exhaust
= 0,5mm (0.020 IN, with hot or cold
engine) at least every 2 years
at least every 2 years
As required
Cleaning, changing the combustion air flter
Bleed the fuel system
Adjust the parking brake
Change the tires
Chang the fresh air flter in the cabin
Tightening torques
Engine conservation
min. 1x every year, safety cartridge at
leastevery 2 years
* Also in case of repairs in the hydraulic system.
Section 5
MAINTENANCE
5-14 4-2012
Danger of injury!
Support the engine hood for all
maintenance and repair work.
NOTE: The service intervals for the water
separator depend on the water content
in the fuel and can therefore not be
determined precisely. After taking
the engine into operation you should
therefore check the water separator every
day for signs of water.
If a to high quantity is drained of, the
flter must be reflled with fuel. See
chapter maintenance as required,
bleeding the fuel system.
Catch runni ng out fuel and di spose of
environmentally.
Fig. 95
Slacken the drain plug (Fig. 95) for a few turns
and catch running out fuel / water. Drain the
filter sump until clear fuel is visible.
Tighten the drain plug again and check for leaks,
if necessary replace the seal ring.
When closing the drain valve, do not overtighten
the valve. Overtightening can damage the
threads.
NOTE: The machine must stand on level ground.
Shut the engine down and wait for
approx. 15 minutes until all oil has run
back into the oil sump.
Fig. 94
Pull the dipstick (Fig. 94) out, wipe it off with
a lint-free, clean cloth and reinsert it until it
bottoms.
Pull the dipstick back out again.
The oil level must be between the L and H-
marks.
Top up oil immediately if the oil level is too low.
If the oil level is too high detect the cause and
drain the oil off.
Before longer work periods you should
always top the oil up to the MAX-mark.
For quality and quantity of oil refer to
the table of fuels and lubricants.
Check the engine oil level Check, clean the water separator
Environment
5-15
Section 5
MAINTENANCE
4-2012
Fig. 96
Check the fuel level on the fuel level gauge n
(Fig. 96) with the ignition switched on.
NOTE: Never drive the fuel tank empty, because
this would required bleeding of the entire
fuel system.
Clean the area around the filler opening.
Fig. 97
Open the fuel tank cover (Fig. 97).
Fire hazard!
When working on the fuel system do
not use open fre, do not smoke, do not
refuel in closed rooms, do not inhale
any fuel fumes.
Checking the fuel level
Cont ami nat ed f uel can cause
malfunction or even damage of the
engine.
If necessary fll in fuel through a screen
flter.
If necessary top up fuel (diesel or winter diesel).
For quality of fuel refer to the table of fuels and
lubricants.
Section 5
MAINTENANCE
5-16 4-2012
Danger of scalding!
Never remove the cap from the
compensation tank when the engine
is hot.
Fig. 98
Check the coolant level (Fig. 98).
If, during the daily inspection the coolant
level is found to have dropped, check all
lines, hoses and engine for leaks.
Do not use any radiator sealing agents
to seal leakages.
Do not fll any cold liquids into a hot
engine.
To top up unscrew the filler cap and fill in coolant
up to the MAX-mark.
For quality of coolant refer to the chapter, fuels and
lubricants.
Fig. 99
Check the hydraulic oil level in the inspection
glass (Fig. 99).
Normal level
approx. 3 cm below the top edge of the inspection
glass.
Minimum level
Middle of inspection glass.
If, during the daily inspection of the oil
level the hydraulic oil level is found to
have dropped, check all lines, hoses and
components for leaks.
If necessary fill in hydraulic oil through the filler
neck.
For quality and quantity of oil refer to the table of
fuels and lubricants.
In hydraulic systems flled with HV68
(TDHType) always use the same oil to
top up.
Checking the hydraulic oil level Checking the coolant level
5-17
Section 5
MAINTENANCE
4-2012
Since the tires are flled with water, you
should always turn the infation valve to
top position to check the tire pressure!
Always close the valves with the dust cap.
Fig. 101
Check the tire pressure with a pressure gauge
and the tire inflation valve 1 (Fig. 101) in top
position.
Nominal value see Technical Data.
NOTE: Ensure even pressure in all tires.
Screw the valve caps back on.
Checking the tire pressure Checking the V-belt
Fig. 100
Inspect the belts daily. Replace the belts if they
are cracked, frayed, or have chunks of material
missing. Small cracks are acceptable.
Adjust the belts that have a glazed or shiny surface,
which indicates belt slippage. Correctly installed
and tensioned belts will show even pulley and belt
wear. Refer to Section 5.29 for belt adjustment
and replacement procedures.
Belt damage can be caused by:
Incorrect tension
Incorrect size or length
Pulley misalignment
Incorrect installation
Severe operating environment
Oil or grease on the belts
Section 5
MAINTENANCE
5-18 4-2012
padfoot drum only
Fig. 103
Check condition and adjustment of scrapers 2
(Fig. 103), adjust or replace the teeth if necessary.
To adjust the scrapers (2) slacken the fastening
screws (1) in the slots and move the scraper
towards the drum, leaving a gap of approx. 25
mm.
Retighten the fastening screws.
(.984in)
smooth drum only
Fig. 102
Check the condition and adjustment of the front
and rear scrapers, adjust or replace the scraper
rubber if necessary.
To adjust the scrapers 1 (Fig. 102) loosen the
fastening screws (2) in the slots and push the
scraper bracket towards the drum until the
scraper touches.
Retighten the fastening screws.
Adjusting the scrapers
5-19
Section 5
MAINTENANCE
4-2012
Fig. 105
Unscrew the filter cartridge (Fig. 105) using an
appropriate filter wrench.
Clean the sealing face on the filter carrier from
any dirt.
Fig. 106
Slightly oil the rubber seal on the new filter
cartridge.
The oil change at 500 operating hours
refers to the use of fuels with a sulphur
content of less than 0.5%.
When using fuels with a sulphur content
higher than 0.5 % the oil change
intervals must be halved (see section
fuels and lubricants).
Drain the engine oil only when the
engine is warm.
Danger of scalding!
When draining of hot oil.
Catch running out oil and dispose of environmentally
together with the engine oil flter cartridge.
Fig. 104
Unscrew the drain plug (Fig. 104) and catch
running out oil.
Turn the drain plug tightly back in.
Changing engine oil and oil flter cartridges
Environment
Section 5
MAINTENANCE
5-20 4-2012
Fig. 107
Turn the new filter cartridge (Fig. 107) on by
hand, until the seal contacts.
Tighten the filter element for another half turn.
Fig. 108
Fill in new engine oil (Fig. 108).
Tighten the oil filler cap properly.
After a short test run check the oil level on the
dipstick, if necessary top up to the top dipstick
mark.
Check filter cartridge and drain plug for leaks
after a short test run.
Shut the engine down and wait for about 15
minutes, so that all oil can flow back into the oil
sump.
Fig. 109
Check the oil level again (Fig. 109), if necessary fill
up to the Max.-mark.
5-21
Section 5
MAINTENANCE
4-2012
Danger of injury!
Perform cleaning work only after the
engine has cooled down and with the
engine stopped.
Do not damage any cooling fns on the
cooler core when cleaning.
NOTE: Dirt on fan blades and oil cooler reduce
the cooling efect. Dirt deposits in these
areas are substantially supported by oil
and fuel on these surfaces. For this reason
you should always seal any oil or fuel leaks
in the vicinity of the cooling fan or the
oil cooler and clean the cooling surfaces
after.
Cleaning with compressed air
Fig. 110
NOTE: Start to blow out from the exhaust side.
Blow the cooler (Fig. 110) out with compressed
air.
Clean the cooling fns on engine and
hydraulic oil cooler
Cleaning with cold cleansing agent
Protect electrical equipment such as
generator, regulator and starter against
the direct water jet.
Spray the engine with a suitable cleansing agent,
e.g. cold cleanser, let it soak in for a while and
spray it off with a strong water jet.
Run the engine warm for a while to avoid
corrosion.
Section 5
MAINTENANCE
5-22 4-2012
Check the oil level in the drive axle Checking the oil level in the left/right hand
planetary drives
Fig. 111
Unscrew the oil level inspection plug (Fig. 111)
and check the oil level.
The oil level must reach the bottom edge of the level
bore.
Top up oil, if necessary.
For quality of oil refer to the table of fuels and
lubricants.
Turn the level inspection plug tightly back in.
Fig. 112
Drive the machine, until both plugs 1 (Fig. 112)
are in horizontal position.
Clean the plug and screw it out.
The oil level must reach the lower edge of the bore,
top up oil if necessary.
lubricants.
Screw the plug tightly back in.
Repeat the same procedure on the opposite side.
5-23
Section 5
MAINTENANCE
4-2012
Only DH and PDH machines
Fig. 114
Move the machine until one plug 1 (Fig. 114) is in
horizontal and one plug (2) in top position.
Clean and unscrew plug (1).
The oil level must reach the bottom edge of the bore.
If necessary clean and unscrew plug (2) and fill in
oil.
lubricants.
Fig. 113
Drive the machine until the oil level control plug
1 (Fig. 113) is vertically below the hub.
The oil level must reach the lower edge of the bore
If necessary top up oil through the filler and drain
bore (2).
lubricants.
Checking the oil level in the
vibration bearing
Checking the oil level in the
drum drive gear
Section 5
MAINTENANCE
5-24 4-2012
Exhausted batteries (batteries with
formation of suphate on the plates are
not covered under warranty!
Remove the four screws holding the cover to
expose the battery.
Fig. 115
Remove the battery (Fig. 115) and clean the
battery compartment.
Clean the outside of the battery.
Clean battery poles and pole clamps and grease
them with pole grease (Vaseline).
Check the fastening of the battery.
On serviceable batteries check the acid level, if
necessary top up to the filling mark with distilled
water.
Charging voltage recommendation
Fig. 116
Danger of cauterisation! Danger of
explosion!
When working on the battery do not use
open fre, do not smoke!
The battery contains acid. Do not let acid
come in contact with skin or clothes!
Wear protective clothing!
Do not lay any tools on the battery!
Dispose of the old battery environmentally.
NOTE: Maintenance free batteries also need care.
Maintenance free only means that the
fuid level does not need to be checked.
Each battery sufers under self-discharge,
which may, in not checked occasionally,
even cause damage to the battery as a
result of exhaustive discharge.
The following therefore applies for the service life:
Switch off all consumers (e.g. ignition, light,
inside light, radio).
Check open-circuit voltage of the battery at
regular intervals. At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V = 50%
discharged.
Recharge the battery immediately after an open-
circuit voltage of 12.25 V or less is reached. Do
not perform boost charging.
The open-circuit voltage of the battery occurs approx.
10 hours after the last charging process or one hour
after the last discharge.
After each charging process allow the battery to
rest for one hour before taking it into service.
For resting periods of more than one month you
should always disconnect the battery. Do not
forget to perform regular open-circuit voltage
measurements.
Service the battery
Environment
5-25
Section 5
MAINTENANCE
4-2012
Fire hazard!
When working on the fuel system do not
use open fre, do not smoke.
Do not spill any fuel.
Catch running out fuel, do not let it seep
into the ground.
Do not inhale any fuel fumes.
Fig. 117
Unscrew the drain plug (Fig. 117) from the
bottom of the fuel tank and drain off approx. 5
litres of fuel.
Screw the drain plug back in with a new sealing
ring.
Draining the fuel tank sludge
Section 5
MAINTENANCE
5-26 4-2012
Fire hazard!
use open fre, do not smoke and do not
spill any fuel.
into the ground.
Loosen and unscrew the fuel filter cartridge (Fig.
118) using an appropriate filter wrench.
any dirt.
The fuel filter has a electrical water in fuel sensor
located in the water drain assembly located on
the bottom of the fuel filter. Disconnect the
electrical connection to the bottom of the fuel
filter at the electrical pigtail.
Fig. 118
Unscrew the fuel filter cartridge using an
appropriate filter wrench.
any dirt.
Unscrew the water separator from the filter
cartridge.
Apply a thin coat of oil to the rubber seal of the
water separator 1 (Fig. 121).
Screw the water separator on by hand (2), until
the seal contacts.
Tighten the water separator for another half turn
(3).
Change the fuel flter cartridge
Fig. 119
Do not pre-fill the on-engine fuel filter with fuel.
The system must be primed after the fuel filter
is installed. Pre-filling the fuel filter can result in
debris entering the fuel system and damaging
fuel system components.
Apply some oil to the rubber seal of the filter
element (4) and screw it on by hand, until the
seal contacts.
Tighten the filter element for another half turn
(5). Torque Value: 34 Nm [25 ft-lb]
Check the filter cartridge for leaks after a short
test run.
Mechanical overtightening will distort the
threads, filter element seal, or filter can.
Use the correct fuel filter.
To prime the engine use the OEM installed
priming device. The priming pump is
installed at the prefilter. Turn priming valve
counterclockwise until pump moves freely. Pump
until resistance is felt, then turn priming valve
clockwise until snug. DO NOT USE TOOLS.
5-27
Section 5
MAINTENANCE
4-2012
Fire hazard!
use open fre, do not smoke and do not
spill any fuel.
into the ground.
Fig. 122
Restrict the fuel line before and after the pre fuel
filter by clamping.
Loosen the hose clamps before and after the pre
fuel filter.
Remove the old pre fuel filter and replace with a
new pre fuel filter.
Replace and secure the hose clamps.
Remove the clamps restricting the fuel lines.
Change the fuel pre-flter cartridge
Fig. 121
NOTE: It is not necessary to vent air from the
high pressure system before starting the
engine.
The fuel pump high-pressure fuel lines and fuel
rail contain very high-pressure fuel. Never loosen
any fittings while the engine is running. Personal
injury and propertydamage can result.
Section 5
MAINTENANCE
5-28 4-2012
Cooling Fan V-belt,
Removal and Installation
Fig. 123
Remove the drive bet by loosening the alternator
mounting capscrew (3) and the belt tension
adjustment capscrew (2).
Move the alternator down the adjustment bar
until the drive belt is loose.
Remove the drive belt.
Fig. 124
Check the condition of the V-belt (Fig. 124).
Small cracks in transverse direction are
permitted.
Cracks in longitudinal direction are not
permitted.
Replace the V-belt in case of broken out material,
intersecting cracks in longitudinal and transverse
direction or fraying.
Fig. 125
Install the drive belt
Using a breaker bar, raise the alternator on
the adjustment bar (1), and adjust the fan belt
tension to specifcations.
Fig. 126
We recommend using the Cummins V-belt
tension tester (Fig. 126) Cummins Part. No.
322524 or a Burroughs gauge Part. No. ST-1138.
For cogged belts, make sure that the belt tension
gauge is positioned so that the center tensioning
leg is placed directly over the high point (hump)
of a cog. Other positioning will result in incorrect
measurement.
Nominal value:
400 to 467 N (90 to105 lb) New Belt
266 to 233 N (60 to 75lb) Used Belt
5-29
Section 5
MAINTENANCE
4-2012
Danger of injury!
Work on the V-belt must only be
performed with the engine shut down.
Checking the V-belt
Fig. 127
Inspect the entire circumference of the V-belt
(Fig. 127) visually for damage and cracks. Replace
damaged or cracked V-belts.
Check with thumb pressure whether the V-belt
can be depressed more than 10 to 15 mm (0.4
0.6 inches) between the V-belt pulleys, retighten
if necessary.
Tensioning the V-belt
Fig. 128
Slightly slacken the fastening screws 1, 2 and 3
(Fig. 128).
Insert a 1/2-inch drive into the 1/2-inch square
bracket hole (4), then rotate in the direction of
the arrows until the correct V-belt tension is
reached.
Retighten all fastening screws.
Changing the V-belt
Slightly slacken the fastening screws 1, 2 and 3.
Release the V-belt tension.
Take the old V-belt off.
Fit the new V-belt to the V-belt pulleys.
Tension the V-belt as previously described.
Check the V-belt tension after a running
time of 30 minutes.
3
1
2
4
Check condition and tension of refrigerant
(optional) compressor V-belt,
replace the V-belt
Section 5
MAINTENANCE
5-30 4-2012
NOTE: On other axle versions drain and fller
plugs are of slightly diferent design.
Perform the oil change accordingly.
Drain oil only at operating temperature.
Catch old oil and dispose of environmentally.
Fig. 129
Clean and unscrew all level inspection and drain
plugs (Fig. 129).
Drain and catch all oil.
Clean the drain plug and turn it back in with a
new seal ring.
Fig. 130
Fill in oil through the oil level inspection bores
(Fig. 130), until it has reached the bottom edge of
the bore.
Retighten the filler and level inspection plug.
Change the oil in the drive axle
Environment
5-31
Section 5
MAINTENANCE
4-2012
Drain the oil only at operating
temperature.
Change the oil on both sides of the axle.
Catch the old oil and dispose of environmetally.
Fig. 131
Move the drive wheel until the plug (Fig. 131) is
in lowest position.
Drain the oil off and catch it.
Fig. 132
Move the drive wheel until the plug (Fig. 132) in
the housing is in horizontal position.
Fill in oil, until it reaches the lower edge of the
bore.
Screw the plug back in.
Repeat the oil change on the opposite side.
Change the oil in the planetary drive
Environment
Section 5
MAINTENANCE
5-32 4-2012
Only DH and PDH machines
Fig. 133
Move the drum, until the drain and level inspection
plug 2 (Fig. 133) is in bottom position.
Clean and unscrew the oil fller plug (1) as well as the
drain and level inspection plug.
Catch running out oil.
Fig. 134
Once all oil has been drained off move the
drum, until the oil filler plug 2 (Fig. 134) is in top
position and the drain and level inspection plug
(1) is in horizontal position.
Fill in oil, until it starts to run out through the
level inspection bore.
Turn filler plug (2) and drain and level inspection
plug (1) tightly back in.
Change the oil in the drum drive gear
Environment
5-33
Section 5
MAINTENANCE
4-2012
Fig. 135
Move the drum until the drain plug 2 (Fig. 135) is
in lowest position.
Clean the oil level control plug (1) as well as the
drain and filler plug and screw them out.
Catch running out oil.
Fig. 136
Once the oil has run out move the drum until the
oil level control opening 1 (Fig. 136) is vertically
below the hub.
Fill in oil until it starts to run out through the oil
level control bore.
Changing the oil in the vibration bearings
Environment
Fit oil level control plug (1) and drain and filler
plug (2) with new sealing rings and screw them
back in.
Section 5
MAINTENANCE
5-34 4-2012
Fig. 138
Check all fastening nuts on axle mounting bolts
(Fig. 138) for tight fit.
Retighten the fastening of the axle on the
frame
Checking the fastening elements
on the engine
Fig. 137
Check the fastening of air intake and exhaust
tube (Fig. 137) on the cylinder heads for tight fit.
Check the bellows and clamps between air filter,
turbo charger and charge air line as well as the
lubrication oil line for tight fit.
Check the fastening screws for the oil sump and
the engine mounts for tight fit.
5-35
Section 5
MAINTENANCE
4-2012
Fig. 139
Tighten the wheel nuts (Fig. 139) in a cross-type
pattern.
Tightening the wheel nuts Checking the ROPS
Fig. 140
Check the cabin, especially the ROPS (Fig. 140) for
cracks, corrosion, damage and missing fastening
elements.
NOTE: Unusual movements and noises
(vibrations) during operation indicate
damage or loose fastening elements.
Check the fastening screws for the cabin (ROPS)
to the operators platform for tight fit.
Check the suspension buffers for the operators
stand for tight fit.
Check the condition and the fastening of the seat
belt.
NOTE: On machines with a ftted cabin the
ROPS (Roll Over Protection Structure) is
integrated in the cabin.
Please observe also the respective section
in the safety regulations in this manual.
Section 5
MAINTENANCE
5-36 4-2012
Fig. 143
Removing the Rocker Lever Cover Remove the
three locknuts, isolator assemblies, o-rings, and
rocker lever cover. Remove the gasket. Discard
the gasket.
Fig. 144
Clean and Inspect for Reuse
Wear appropri ate eye and face
protection when using compressed
air. Flying debris and dirt can cause
personal injury.
Clean the rocker lever cover with a
strong solution of detergent in hot
water. Dry the rocker lever cover with
compressed air.
Inspect the rocker lever cover for cracks
and other damage.
Before checking the valve clearance
let the engine cool down for at least
30 minutes. The engine temperature
should be lower than 60 C.
Remove the air filter.
Fig. 141
Remove the crankcase breather tube from the
rocker lever cover.
Fig. 142
Clean and Inspect for Reuse
Wear appropri ate eye and face
protection when using compressed
air. Flying debris and dirt can cause
personal injury.
If the crankcase breather tube is blocked
with obstructions or sludge buildup,
the tube must be cleaned with a strong
solution of detergent in hot water or
replaced to prevent excessive crankcase
pressure buildup. Dry the crankcase
breather tube with compressed air.
Inspect the crankcase breather tube for
cracks, or other debris, that can obstruct
the tube.
Checking, adjusting the valve clearance
5-37
Section 5
MAINTENANCE
4-2012
Fig. 147
Adjust intake and exhaust clearances in the
following firing order by rotating the crankshaft
180 degrees clockwise (1-2-4-3 firing order) or
use the following procedure to adjust in two
locations:
1. Number 1 cylinder at top dead center (TDC)
2. Rotate 360 degrees.
Fig. 148
Adjust the valve clearance for the intake valves
number 1 and number 3.
Adjust the valve clearance for the exhaust valves
Fig. 145
Overhead Set Adjustment
Rotate the crankshaft in the normal direction
(Clockwise).
Check the movement of the intake valve number
4 cylinder. The number 4-cylinder intake valve
will start to open when the number 1 cylinder
comes near the compression top dead center
(TDC).
Rotate the number 1 cylinder into compression
top dead center (TDC) position.
Align the TOP engraved mark on the crankshaft
pulley (1) with the pointer (2). The engraved
mark on the crankshaft pulley will read 1.4 TOP.
Fig. 146
Loosen the locknut (3) on the adjustment screw
(4). Insert the feeler gauge (5) between the
valve stem (6) and the rocker arm (7). Adjust the
clearance with the adjustment screw until slight
drag is felt on the feeler gauge.
Valve Clearance (Engine Hot or Cold)
Intake Valve Exhaust Valve
0.35 mm [0.014 in] 0.50 mm [0.020 in]
Section 5
MAINTENANCE
5-38 4-2012
Fig. 149
Tighten the locknut to secure the adjustment
screw.
Fig. 150
Rotate the crankshaft in the normal direction one
revolution. Adjust the valve clearance for the intake
valves number 2 and number 4.
Adjust the valve clearance for the exhaust valves
Fig. 152
Reinstalling the rocker lever cover.
Install the new gasket.
Install the rocker lever cover, o-rings, isolator
assemblies, and locknuts.
Torque Value: 9 Nm [ 80 in-lb ]
Fig. 151
Tighten the locknut to secure the adjustment
screw.
Locknut Torque Value
Nm ft-lb
39 MIN 29
49 MAX 36
Locknut Torque Value
Nm ft-lb
39 MIN 29
49 MAX 36
5-39
Section 5
MAINTENANCE
4-2012
Fig. 153
Unscrew the plug (Fig. 153) and drain the
hydraulic oil off.
Check the sealing ring (1), replace if necessary
and screw the plug tightly back in.
Fig. 154
Take the filler cap (Fig. 154) off.
Fill in hydraulic oil through the screen.
NOTE: We recommend to use the flling and
fltering unit (part-no. 079 930 35) with
fne flter to fll the hydraulic system.
This flters the hydraulic oil, prolongs the
service life of the hydraulic oil flter and
protects the hydraulic system.
Check the oil level in the inspection glass.
Nominal value:
approx. 3 cm below the upper edge of the inspection
glass
NOTE: See also section Notes on the Hydraulic
System.
Apart from the normal oil change
intervals the hydraulic oil must also
be changed after major repairs in the
hydraulic system.
Change the hydraulic oil only at
operating temperature.
Clean the area around the hydraulic oil
tank, the fller opening and the breather
flter.
Do not use any detergents to clean the
system.
Do not start the engine after draining
the hydraulic oil.
Change the hydraulic oil flter element
with every hydraulic oil change.
Danger of scalding!
Danger of scalding by hot oil.
Catch running out oil and dispose of
environmentally.
NOTE: The hydraulic oil flter element should
only be changed after the test run.
Changing the hydraulic oil and the
breather flter
Environment
Section 5
MAINTENANCE
5-40 4-2012
Changing the hydraulic oil flter
Fig. 155
Unscrew the cap nut 4 (Fig. 155) and take the
filter bowl (5) with the filter element (3) off.
Examine the sealing face on the filter element
thoroughly for any visible dirt.
Visible impurities can be an early
indicator for a premature failure of
system components and a possible
malfunction of parts. In such a case
perform trouble shooting and, if
necessary, replace or repair defective
components. Negligance may damage
the complete hydraulic system.
Do not clean or reuse the flter
element.
Danger of scalding!
There is a danger of scalding by hot oil
when unscrewing the flter.
If the flter has to be changed together
with the hydraulic oil, the flter should in
any case be changed after the oil change
and the test run.
Do not use the oil in the flter bowl.
Catch running out oil, dispose of oil and flter
element environmentally.
NOTE: The flter element must be changed with
every hydraulic oil change and after major
repairs in the hydraulic system.
Environment
NOTE: The breather flter for the hydraulic tank is
located in the fller cap and must therefore
be replaced with the fller cap.
Close the tank with the new filler cap.
5-41
Section 5
MAINTENANCE
4-2012
Danger of scalding!
Change the coolant only when the
engine is cold.
Catch running out coolant and dispose of
environmentally.
Fig. 156
Switch the control valve (Fig. 156) for the cabin
heater to warm.
Fig. 157
Unscrew the drain plug, drain all coolant off and
catch it.
Screw the plug back in after all coolant has been
drained off.
Changing the coolant
Environment
Take the old filter element (3) out and clean the
filter bowl and the thread.
Reinstall the filter bowl with the new filter
element, check the condition of the O-rings (1)
and (2), replace if necessary.
After a test run check the filter for leaks.
Section 5
MAINTENANCE
5-42 4-2012
Fig. 158
Unscrew the cap and fill in coolant up to the
MAX-mark. (Fig. 158)
For quality of coolant refer to the chapter, fuels and
lubricants.
Start the diesel engine and run it warm to
operating temperature.
Let the engine cool down and check the coolant
level again, top up if necessary.
5-43
Section 5
MAINTENANCE
4-2012
Maintenance of the dry air flter is due when indicated
by the Air flter restriction indicator located on the side
of the engine. (Fig. 159) Maintenance of the Air flter
must minimally occur after one year.
Fig. 160
Open the engine hood (Fig. 160) completely and
secure it.
Removing the main flter element
Fig. 161
Loosen both locking hooks (Fig. 161) on the
housing cover and take the cover off.
Perform cleaning, maintenance and
repair work only with the engine shut
down. Do not start the engine after
removing the flter element.
Do not use gasoline or hot fuids to clean
the flter element.
After cleaning the flter element must
be inspected for damage using a torch.
Air flter elements with damaged paper
bellows or seal lips must be replaced in
any case.
The main flter element must be replaced
after 3 times cleaning, but at the latest
after one year, irrespective of the
operating hours.
Each cleaning interval must be marked
with a cross on the cover of the flter
element.
Cleaning does not make sense if the air
flter element is covered with a sooty
deposit. Use a new flter element.
Incorrectly handled flter elements may
become inefective because of damage
(e.g.: cracks) and cause engine damage.
Fig. 159
Cleaning, changing the
dry air flter cartridge
Section 5
MAINTENANCE
5-44 4-2012
Fig. 163
Blow the filter cartridge out from inside to
outside with dry compressed air (max. 5 bar)
(Fig. 163), until all dust has been removed.
Fig. 164
Examine the filter cartridge with a lamp for cracks
and holes in the paper bellows (Fig. 164).
Do not continue to run the machine
with a damaged main flter element. If
in doubt use a new main flter element.
Fig. 162
Pull out the main filter element (Fig. 162) with
light turning movements.
Cleaning the main flter element
If necessary, the main flter element may
be cleaned up to fve times. It must be
renewed at the latest after a maximum
utilization period of two years.
The number of cleaning intervals of the
main flter element can be marked on
the safety element with a ballpoint pen
or a felt pen.
Cleaning does not make sense if the
main flter element is covered with a
sooty deposit. Use a new flter cartridge.
Incorrectly handled inserts may be
ineffective because of damage (e.g.
cracks) and cause damage to the engine.
Replace the safety cartridge if the main
flter element is defective!
Additional cleaning intervals between
two flter services signalized by the fault
monitoring board are not necessary.
5-45
Section 5
MAINTENANCE
4-2012
Remove the housing cover and pull the main
filter element off.
Fig. 166
Pull the safety element (Fig. 166) out by slight
turning movements.
Push in a new safety filter element.
Reassemble main filter element and cover.
Make sure that the cover locks engage
correctly.
Cleaning the dust bowl
Fig. 165
Pull the internal part (Fig. 165) out and remove
the dust from the cover.
Reinsert the inner part.
When assembling the inner part make
sure that the notch in the cover engages
in the opening of the inner part.
Installing the main flter element
Slide the main filter element carefully into the
housing.
When closing the housing cover the main flter element
is automatically forced in the correct position.
Changing the safety flter element
The safety flter element must not be
cleaned and should not be used again
after it has been removed.
Break the seal only to replace the safety
flter element.
The safety filter element must be
replaced:
If the main flter element is defective.
after fve service intervals of the flter
cartridge,
at the latest after 2 years, if the warning
light comes on again after servicing the
main flter cartridge.
Section 5
MAINTENANCE
5-46 4-2012
Refer to the Cummins Operation and Maintenance
Manual Bulletin 3666417
Bleeding the fuel system
5-47
Section 5
MAINTENANCE
4-2012
Fig. 169
To adjust the clearance turn the square 1
(Fig. 169) three revolutions back in clockwise
direction.
Screw the locking plate back on.
Pull the plug off the brake valve and try to drive.
The machine must be braked.
Have adjustment work on the brake
performed by a specialist! Always
adjust both sides.
Secure the machine with chocks against
Start the diesel engine to release the brake.
Fig. 167
Unlock the travel lever (Fig. 167) by pushing it to
the left, but do not actuate it to position I or II.
The parking brake is released
Fig. 168
Unscrew the locking plate 2 (Fig. 168).
Turn the square (1) in anti-clockwise direction
against the end stop.
Adjusting the parking brake
Section 5
MAINTENANCE
5-48 4-2012
Fig. 171
Unscrew fastening screws for the ventilation grid
(Fig. 171) and remove the filter.
Insert a new filter and reassemble the ventilation
grid.
Danger of accident!
Observe all safety notes for the lifting
of loads.
Place a jack (min. 5 t bearing capacity) under the
rear frame and jack the machine up so that the
wheel can turn freely.
Unscrew the wheel nuts and take the wheel off.
Fig. 170
Attach the wheel (Fig. 170) and tighten the wheel
nuts crosswise with 550 Nm (405 ft. lb.).
Check the tire pressure, see technical data.
Changing the tires Changing the fresh air flter in the cabin
5-49
Section 5
MAINTENANCE
4-2012
Fig. 167
* Strength classes for screws with untreated, non-
lubricated surface. Screw quality designations are
stamped on the screw heads.
Axle - frame
M 24 = 710 Nm (649.0 ft.lbs.)
Wheel nuts
M 22x1.5 = 550 Nm (405.7 ft.lbs.)
The values result in a 90% utilization of the screw
yield point at a coefcient of friction total = 0,14.
When using lubricant MOS
2
the specifed tightening
torques do not apply.
NOTE: Self-locking nuts must always be replaced
once they have been unscrewed.
Tightening torques Engine conservation
BOLT
DIMENSIONS
TIGHTENING TORQUE
FT. LBS. / Nm
8.8 10.9 12.9
M4
2 ft. lbs./3 Nm 3 ft. lbs./5 Nm 4 ft. lbs./5 Nm
M5
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
524 ft. lbs./711 Nm
738 ft. lbs./1000
Nm
885 ft. lbs./1200
Nm
M27
774 ft. lbs./1050
Nm
1092 ft. lbs./1480
Nm
1308 ft. lbs./1774
Nm
M30
1047 ft. lbs./1420
Nm
1482 ft. lbs./2010
Nm
1770 ft. lbs./2400
Nm
If the engine is to be shut down for a longer period of
time (e.g. over winter), we recommend to apply the
following conserving measures to avoid corrosion:
Clean the engine, including the cooling system:
With cold cleansing agent and a water jet or,
even better, with a steam cleaner.
Run the engine warm and shut it down.
Drain off the still hot engine oil and fill in anti-
corrosion engine oil.
Drain off the coolant and fill in system protection
agent.
Drain the fuel from the tank, mix it well with 10%
anti-corrosion oil and fill it back in.
Run the engine for 10 minutes until all lines,
filters, pumps and nozzles with this conserving
mixture and the new engine oil has been
distributed to all parts.
Now crank the engine several times (without
ignition) to spray the combustion chambers.
Take the V-belts off and spray the grooves of the
V-belts with anti-corrosion oil. Remove the anti-
corrosion oil before resuming operation.
Close intake and exhaust openings tightly.
NOTE: Depending on the weather conditions
these con-serving measures will provide
protection for approx. 6 to 12 months.
Before taking the engine back into
operation all conserving oil must be
drained of and replaced by regular
engine oil, see chapter Fuels and
Lubricants according to the API-(MIL)-
classifcation.
Anti-corrosion oils are those that comply with the
specifcation MIL-L-21260 B or TL 9150-037/2 or Nato
Code C 640/642.
A machine with a conserved engine must be marked
by attaching a clearly visible warning tag.
8.8 = 8G
10.9 = 10K
12.9 = 12K
Section 5
MAINTENANCE
5-50 4-2012
NOTES
6-1
Section 6
TROUBLE SHOOTING
4-2012
TABLE OF CONTENTS
PAGE
GENERAL NOTES ........................................................................................................................... 2
ENGINE ........................................................................................................................................... 3
OPTIONAL PAD FOOT/SMOOTH SHELL KIT MAINTENANCE ................................................... 5
6-2
Section 6
TROUBLE SHOOTING
4-2012
The following work must only be carried out by
qualifed and trained personnel or by the sales
service.
Please observe strictly the safety regulations in
chapter 2 of these operating and maintenance
instructions.
Faults occur frequently due to the fact, that the
machine has not been properly operated or serviced.
Therefore, whenever a fault occurs, read through these
instructions on correct operation and maintenance. If
you cannot locate the cause of the fault or eliminate it
yourself by following the trouble shooting charts, you
should contact our customer service departments at
our branch ofce or dealers.
Danger of injury!
Keep away from rotating parts of the
engine.
General notes
6-3
Section 6
TROUBLE SHOOTING
4-2012
Engine
Faults Possible cause Remedy
The engine does
not start
Starter defective or pinion not engaging
Fuel tank empty
Temperature below starting limit
Fuel flter clogged, in winter due to parafn
separation.
Fuel lines leaking
Battery discharged or not conected
Injection valves or injection pump defective
Have examined by a specialist
Fill and bleed the tank
Use winter fuel and engine oil acc. to the
ambient temperature.
Change the flter. use winter fuel
Check all line connections for leakages and
tighten the fttings.
Tighten the pole clamps, check the cable
connections.
The engine
starts poorly and
works irregularly
with poor power
Battery power too low, battery clamps loose
or oxidized, causing the starter to turn too
slowly
Especially during winter: the use of too
viscous engine oil
Fuel supply restricted, in winter fuel system
clogged due to parafn separation
Incorrect valve clearance
Injection valve defective
Injection lines leaking
Turbo charger defective
Dry air flter dirty
Excessive play in the throttle cable
Have the battery checked, clean the
terminal clamps, tighten them and cover
them with acid free grease
Use engine oil suitable for the ambient
temperature
Change the fuel flter. Check the line
connections for leaks and tighten the
fttings. Use winter fuel in the cold season.
Adjust the valve clearance
Check the lines for leakages
clean, replace if necessary
Adjust the throttle cable, change it if
necessary
6-4
Section 6
TROUBLE SHOOTING
4-2012
Faults Possible cause Remedy
Excessive
exhaust smoke
Engine oil level too high
Dry air flter dirty
Exhaust gas turbocharger defective
Poor compression due to burned or broken
compression rings or incorrect valve
clearance
Drain the oil to the upper dipstick mark
Clean, replace if necessary
Have compression rings and pistons
examined by a specialist, adjust the valve
clearance
Engine
over-heats,
shut down
immediately!
Cooling fns on radiator extremely soiled
(the warning light engine oil temperature
lights)
Engine oil level too low
Filling capacity of the injection pump not
correctly adjusted
Cooling air fow restricted
V-belt lose or broken
Clean the cooling fns

Top up engine oil to the upper dipstick mark
Have adjusted by a specialist
Clean the cooling air duct
Tension or replace the V-belt
Poor engine
power
Engine oil level too high
Dry air flter dirty
Exhaust gas turbo-charger defective
Charge air hose leaking
Drain the engine oil down to the upper
dipstick mark
Clean, change if necessary
Check fastening and connections
Engine oil
pressure too low
Engine oil level too low (control light
engine oil pressure lights, the warning
buzzer sounds)
Leakages in the lubrication system
Top up oil

Shut the engine down immediately, check
fttings on oil lines, lubrication oil flter and
oil cooler for leaks, if necessary tighten the
fttings.
The charge
control light
lights during
operation, the
warning buzzer
sounds
Generator speed too low
The generator does not charge the battery,
because generator or regulator is defective
Check the V-belt tension, replace the V-belt
if necessary
6-5
Section 6
TROUBLE SHOOTING
4-2012
Smooth shell kit
Smooth Hardware Torque specifcations:
Items 1 and 2.
BW145PDH, BW177PDH, C822 C232:
Grade 10.9 bolt/nut combination 236 ft. lb. (320 Nm).
30 Bolts.
BW211PD, BW213PDH, C842, C852:
Grade 10.9 bolt/nut combination 427 ft. lb. (580 Nm).
30 Bolts.
Smooth shell kit torque sequence.
First torque the bolt at the A postion, then the 2 bolts
at the B postion and then the 2 bolts at the C postion
on both sides of the drum. Repeat the process for the
remaining sections. Recheck the torque values.
4
3
2
1
2
1
Units equipped with the optional
Pad foot or Smooth shell kit requires
maintenance. Failure to perform
required maintenance will result in a
shorten equipment life cycle and the
voiding of the warranty.
Units covered under this maintenance information are:
Pad foot shell kit:
BOMAG: BW145D/DH, BW177D/DH, BW211D,
BW213D/DH
HYPAC: C820, C830 and C850 series of single drum
rollers.
Smooth shell Kit:
BOMAG: BW145PDH, BW177PDH, BW211PD,
BW213PDH
HYPAC: C822, C832, C842, C852
Maintenance must be performed every
50 hours or weekly which ever comes
frst. Failure to comply with the required
maintenance with result in the voiding
of the warranty.
Pad foot shell kit
Pad foot Hardware Torque specifcations:
Items 1 and 2. Grade 10.9 bolt/nut combination 221
ft. lb. (300 Nm). 2 Bolts.
Items 3 and 4. Grade 8.8 bolt/nut combina-tion 156
ft. lb. (212 Nm). 18 Bolts.
Addendum
A
B
B
C
C
Optional Pad foot/Smooth Shell Kit
Maintenance
2000 Kentville Road Kewanee,
Illinois 61443
U.S.A.
Tel.: (309) 853-3571
Fax: (309) 852-0350 e-mail:
usa@bomag.com
BOMAG (Canada), Inc.
13000 Areowood Drive
Mississauga, Ontario L4W 1B7
CANADA
Tel.: (905) 625-6611
Fax: (905) 625-9570 e-mail:
canada@bomag.com
Printed in U.S.A.
2000 Kentville Rd.
Kewanee, IL 61443
Catalog Number
0852820 4/12
Operating Instructions
Maintenance Instructions
BW177D-50 / BW177DH-50 / BW177PDH-50
SN: 901582301001 > SN: 901582311001 >
SN: 901582321001 >
Single Drum Vibratory Roller

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